Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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MAILPIECES THAT MITIGATE FLEXURE OF HELD ARTICLES DURING
AUTOMATED HANDLING
Cross-Reference to Related Applications
[0001] This application is a continuation-in-part of Application No.
11/610,675, filed on
December 14, 2006, which claims the benefit of U.S. Provisional Application
No. 60/805,416,
filed June 21, 2006, the disclosure of each document is hereby incorporated by
reference herein
in its entirety.
Field of the Invention
[0002] The invention relates to mailpieces and, in particular, to mailpieces
and mailpiece
assemblies that are suitable for securing and protecting articles, such as
stress-sensitive or
frangible articles, to ensure safe processing by automated processing
equipment.
Background of the Invention
[0003] Mailpieces are routinely employed for mailing breakable, frangible or
stress-
sensitive articles, such as DVD's, compact disks (CD's), and mini-CD's. Most
mass mailings of
frangible articles consist of letter-sized mailpieces, which are pre-sorted
before possession is
transferred to a postal service, such as the United States Postal Service. The
pre-sorting qualifies
the mass mailing for reduced postage rates because it easier for the United
States Postal Service
to sort and deliver the mail using automated equipment. To qualify for reduced
postage rates,
however, the processed mail must meet certain criteria set forth in various
postal regulations.
[0004] Postal services sort large volumes of mail with high-speed automated
processing
equipment having drums, transport rollers, and pairs of opposing belts that
grip and transport
individual mailpieces at a volume of up to 40,000 pieces an hour. The
automated processing
equipment conveys the mailpieces at speeds approaching 500 to 600 feet per
minute along a feed
path. Various functions may be performed on the mailpieces at different
locations along the feed
path. For example, an optical scanner provided adjacent to the feed path
identifies a destination
address for each mailpiece. Ultimately, the mailpieces are sorted according to
the destination
address and routed along the feed path into assorted bins or stackers.
[0005] The rollers used to support the belts, which have a width approximately
equal to
the roller height, are crowned. The vertical convex shape of the crowned
rollers keeps the belts
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tracking properly within the machinery and in the correct position on the
rollers. The opposing
belts are kept under tension to be able to hold and transport mailpieces
through the machinery of
the automated processing equipment. As the belts move through and change
direction within the
machinery, the tension of the belts exerts pressure on the rollers. Changes in
direction are
accommodated by providing a pulley, roller or drum over which the moving belts
are trained at
the change-of-direction point. For example, if the mailpiece is moving
linearly in a horizontal
direction and it is desired to effect a directional change to a different
horizontal direction, a
rotatable drum is placed at the change-of-direction point in the path of
travel of the opposed
belts. As the belts move about the rotating drum, the mailpiece travels
through a curved path
conforming to the drum periphery and emerges traveling between the moving
belts in the
different horizontal direction.
[0006] Letter-size mailpieces are constructed to comply with postal
regulations, such as
dimensional requirements, address positioning, and flexibility. Specifically,
postal regulations
require the mailpiece to be flexible enough to be bent and routed about the
circumference of
cylindrical pulleys, rollers and drums of the type used in automated
processing systems. The
United States Postal Service currently states that all letter-sized mailpieces
must easily bend
under 40 pounds of exerted belt pressure. If the dimensions of the mailpiece
exceed a maximum
dimension (e.g., are oversized) as governed by postal regulations or the
mailpiece fails to meet
the flexibility requirements for letter sorting equipment, the United States
Postal Service does not
treat the mailpiece as a letter. Instead, the mailpiece is handled as a non-
letter or flat by
automated equipment that does not require routing about the exterior of drums
or rollers. The
postage rate is higher for flats than for letter-sized mailpieces.
[0007] Conventional mailpieces expose stress-sensitive articles to a
significant risk of
damage during processing by automated processing equipment. As the mailpiece
is conveyed
about the exterior of the roller (or pulley or drum), the belt pressure forces
flexible items carried
by the belts to conform to the vertical convex shape of the roller and to bend
or bow horizontally
around the circumference of the roller when the belt changes direction. The
stress-sensitive
article inside the mailpiece must also curve or bow in conformity with the
mailpiece and,
therefore, will experience a state of tension due to the flexure. The
combination of bending to
the vertical convex shape of the roller and bending horizontally around the
circumference of the
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roller is believed to apply significant pressure on the article at the center
of these two divergent
forces. The applied pressure may damage, or even break or fracture, the
article.
[0008] With reference to FIGS. 1, 2, and 3, a pair of confronting conventional
belts 11
(one shown) rides over the surface of a vertically-oriented crown roller 12
mounted with
bearings to an axle or spindle 15 projecting from the support base of a
machine 17. The roller 12
is one of several similar rollers (not shown) used for guiding the belts 11 in
a generally
horizontal direction indicated by the single-headed arrows 14. As the belts 11
move in the
horizontal direction 14, the belts 11 cause the crown roller 12 to rotate
about an axis 15a (FIGS.
2, 3), as indicated by the single headed arrow 113 in FIG. 3. Crown roller 12
includes a
convexly-contoured surface 13 such that the diameter of roller 12 at a
circumference 26 is larger
than the diameter of roller 12 at peripheral rims 30a, 30b.
[0009] A stress-sensitive, frangible article 16, which is contained or
packaged inside of a
mailpiece 22, is gripped on opposites sides by the moving belts 11. Frangible
article 16 may be,
but is not limited to, a CD, DVD, optical disk, or the like, having a hub 18,
a center opening 21
defined in the hub 18, and a media portion 20. The hub 18 and media portion 20
are
concentrically arranged about a central axis 19 of the center opening 21 with
the hub 18 radially
inside of the media portion 20.
[0010] Mailpiece 22, which may have a generally rectangular shape, has a
height, h,
(FIG. 4) greater than the height of article 16, a length, L, and a thickness,
w. The length, L, is
measured generally along the horizontal direction of travel 14. Mailpiece 22
includes two
opposed panels 42, 44, peripheral edges 46, 48 substantially parallel to the
length, L, and lateral
or side edges 50, 52 substantially parallel to the height, h. The peripheral
edges 46, 48 (FIG. 4)
respectively represent the top and bottom edges of the mailpiece 22 when being
conveyed by the
belts 11. The side edges 50, 52 connect the peripheral edges 46, 48.
Peripheral edge 46 may
coincide with a fold line 47 of a flap 56 (FIG. 7).
[0011] The mailpiece 22 and frangible article 16 are conveyed past the crown
roller 12.
As the belts 11 past the crown roller 12 in the horizontal direction 14
transport the mailpiece and
frangible article 16, the hub 18 and/or media portion 20 of the article 16
generally ride over the
surface 13 of the roller 12. The mailpiece 22 prevents direct contact between
the article 16 and
belts 11. At any instant in time, the mailpiece 22 contacts the roller 12
about contact point 24,
which lies on a circumference 26 of the roller 12. As best shown in FIG. 2A,
mailpiece 22
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moves into and out of the plane of the page in a direction generally parallel
to a plane 36 that is
tangent to contact point 24. The moving belts 11 apply belt pressure in a
direction generally
indicated by arrows 28 to the mailpiece 22. As the mailpiece 22 is transported
past the roller 12,
contact point 24 traces a substantially linear path along the length, L, of
the mailpiece 22.
[0012] Frangible article 16 is typically carried inside mailpiece 22 with at
least a portion
of the hub 181ocated between the opposite rims 30a, 30b of roller 12. The
mailpiece 22 and the
article 16, which are somewhat flexible, conform to the convexly contoured
surface 13 of the
crown roller 12 between peripheral rims 30a, 30b under the influence of the
belt pressure 28.
Specifically, mailpiece 22 and article 16 bend or flex to adopt a convex
curvature that
corresponds to the convexly contoured surface 13 of the crown roller 12.
Because of the
curvature of the surface 13 of crown roller 12, the belt pressure 28 bends the
mailpiece 22 and
article 16 in a direction perpendicular to the travel direction 14. The
bending of the mailpiece 22
and article 16 closes the theoretical gaps 32a, 32b (FIG. 2A) defined by the
respective distances
from points 39a, 39b on the rims 30a, 30b to the nearest point along the plane
36, otherwise
present in the absence of pressure symbolized by arrows 28. Each of the panels
42, 44 (FIG. 4)
defining the mailpiece 22, which is relatively thin, operates as a thin
membrane or film that
readily conforms to the shape of the roller 12.
[0013] As best shown in FIG. 3, the mailpiece 22 also bends about the
circumference 26
(FIG. 2) of the roller 12 to conform to the curvature. The frangible article
16, which is
constrained by the mailpiece 22, must likewise flex to assume a curvature that
conforms to the
circumference 26 of the roller 12. Consequently, the belt pressure 28 also
bends the article 16
about the roller 12 in a direction parallel to the travel direction indicated
by arrow 14.
[0014] The bi-directional flexing of the mailpiece 22 and frangible article 16
may
damage the frangible article 16. In one damage mode, the flexing may cause a
fracture to initiate
and propagate in the constituent material(s) of the frangible article 16.
Often, the fracture will
initiate in the hub 18 and propagate radially outwardly into the media portion
20. The fractured
hub 18 of the frangible article 16 may be damaged to an extent that the
frangible article 16
cannot be engaged by a player for retrieving the data encoded in the medial
potion 20.
Alternatively, the fracture may damage the media portion 20 such that any data
encoded in the
media portion 20 is unreadable by the player. Because of this and other
significant
shortcomings, conventional letter-sized mailpieces fail to adequately
safeguard stress-sensitive
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articles when handled by automated processing equipment of the type used by
the United States
Postal Service.
[0015] Accordingly, there is a need for mailpieces and mailpiece assemblies
suitable for
mailing stress-sensitive, frangible articles that can be handled by automated
letter-sized
processing equipment and, moreover, that fully comply with postal regulations
while
simultaneously protecting the article from damage during processing.
Summary of the Invention
[0016] In one embodiment, a mailpiece is provided for mailing an article
having a first
side and a second side opposite to the first side. The mailpiece comprises
first and second panels
that are joined to define a first peripheral edge, a second peripheral edge,
and side edges
separating the second peripheral edge from the first peripheral edge. The
first and second panels
are disposed on the respective opposite sides of the article and the article
is positioned between
the first and second edges. The first panel carries a first spacer. The second
panel carries a
second spacer. The first spacer is disposed between the first side of the
article and the first panel.
The second spacer is disposed between the second side of the article and the
second panel. The
first and second spacers are aligned substantially parallel to the first and
second peripheral edges.
[0017] In another embodiment, a mailpiece is provided for mailing an article
having a
first side and a second side opposite to the first side. The mailpiece
comprises a first panel, a
second panel joined to the first panel to define a first peripheral edge, a
second peripheral edge,
and side edges separating the second peripheral edge from the first peripheral
edge. The
mailpiece further includes a sleeve carrying the article. The sleeve is
disposed between the first
and second panels. The sleeve is also positioned between the first and second
edges. The sleeve
includes a first spacer disposed between the first side of the article and the
first panel, and a
second spacer disposed between the second side of the article and the second
panel. The first and
second spacers are aligned substantially parallel to the first and second
peripheral edges.
[0018] In another embodiment, a mailpiece is provided for mailing an article
having a
first side and a second side opposite to the first side. The mailpiece
comprises a first panel
joined to a second panel to define a first peripheral edge, a second
peripheral edge, and side
edges separating the second peripheral edge from the first peripheral edge.
The first and second
panels are disposed on the respective opposite sides of the article. The
article is positioned
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between the first and second edges. An insert is located between the first and
second panels.
The insert includes a first spacer disposed between the first side of the
article and the first panel
and a second spacer disposed between the second side of the article and the
second panel. The
first and second spacers may be aligned substantially parallel to the first
and second peripheral
edges.
[0019] In another embodiment, a mailpiece is provided for mailing an article
having a
first side and a second side opposite to the first side. The mailpiece
comprises a first panel
joined to a second panel to define a first peripheral edge, a second
peripheral edge, and side
edges separating the second peripheral edge from the first peripheral edge.
The first and second
panels disposed on the respective opposite sides of the article. The article
is positioned between
the first and second edges. First and second inserts are disposed between the
first and second
panels. The first insert includes a first spacer disposed between the first
side of the article and
the first panel. The first insert includes a second spacer disposed between
the second side of the
article and the second panel. The first and second spacers are aligned
substantially parallel to the
first and second peripheral edges.
[0020] In another embodiment, a mailpiece is provided for mailing an article
having a
first side, a second side opposite to the first side, and a center opening
extending between the
first and second sides. The mailpiece comprises a first panel joined to a
second panel to define a
first peripheral edge, a second peripheral edge, and side edges connecting the
first and second
peripheral edges. The first and second panels are disposed on the respective
opposite sides of the
article. The article is positioned between the first and second edges. A
spacer, which may be
carried by the first panel, is adapted to be inserted into the center opening
of the article. The
spacer is at least partially disposed between the first side of the article
and the first panel.
[0021] In another embodiment, an apparatus for use with a mailpiece that
comprises a
frangible article having a first side and a second side opposite to the first
side. The apparatus
further comprises a spacer projecting from the first side of the frangible
article. The spacer is
adapted to be disposed between the first side of the frangible article and the
mailpiece.
[0022] The spacers of the embodiments of the invention operate to reduce one
component of the bi-directional flexing of the mailpiece and the frangible
article carried by the
mailpiece. Specifically, the spacers reduce the flexing of the mailpiece and
frangible article
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relative to the convexly contoured surface of a crown roller. This reduces the
likelihood that the
frangible article will be damaged when handled by automated letter-sized
processing equipment.
[0023] The invention may be used in conjunction with mailpieces shown and
described
in U.S. Patent No. 6,491,160 and in U.S. Publication Nos. 2004/256446 and
2005/224566. The
respective disclosure of each of these patent documents is hereby incorporated
by reference
herein in its entirety.
Brief Description of the Drawings
[0024] The accompanying drawings, which are incorporated in and constitute a
part of
this specification, illustrate embodiments of the invention and, together with
a general
description of the invention given above and the detailed description of the
embodiments given
below, serve to explain the principles of the invention.
[0025] FIG. 1 is an elevational view of an article being transported by belts
riding on a
crown roller with a mailpiece, which is omitted for purposes of illustration,
in accordance with
the prior art.
[0026] FIG. 2 is an end view of an article held by a mailpiece in accordance
with the
prior art in which the mailpiece is being conveyed by belts past a crown
roller and is distorted by
the pressure applied by the belts in which bending about the roller is
uncompensated.
[0027] FIG. 2A is a theoretical end view similar to FIG. 2 of the prior art
mailpiece and
the article in the absence of pressure applied by the belts.
[0028] FIG. 3 is a top view of FIG. 2 demonstrating the bending of the prior
art mailpiece
and article about the circumference of the crown roller and taken along a line
through a
circumference of the crown roller.
[0029] FIG. 4 is an end view of a mailpiece in accordance with an embodiment
of the
invention in which the mailpiece carries gap-filling spacers at respective
locations above and
below the central circumference of the roller.
[0030] FIG. 5A is an end view similar to FIG. 4 of a mailpiece in accordance
with an
embodiment of the invention.
[0031] FIG. 5B is an end view similar to FIG. 5A in which the mailpiece is
conveyed
past the roller with a different side of the mailpiece in contact with the
roller.
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[0032] FIG. 6 is an end view similar to FIG. 4 of a mailpiece in accordance
with another
embodiment of the invention.
[0033] FIG. 7 is a perspective view of a mailpiece in accordance with an
embodiment of
the invention and broken away to show an article held by the mailpiece.
[0034] FIG. 7A is an enlarged view of the encircled area of FIG. 7.
[0035] FIG. 8 is an end view of the mailpiece of FIG. 7.
[0036] FIGS. 9-12 are detailed perspective views similar to FIG. 7A of
mailpieces in
accordance with alternative embodiments of the invention.
[0037] FIG. 13A is a perspective view of a mailpiece comprising an envelope
and a
sleeve inserted into the envelope in accordance with an alternative embodiment
of the invention.
[0038] FIG. 13B is an end cross-sectional view of the mailpiece of FIG. 13A.
[0039] FIG. 13C is a perspective view of a sleeve for the mailpiece of FIG.
13A in
accordance with an alternative embodiment of the invention.
[0040] FIG. 13D is an end cross-sectional view of the sleeve of FIG. 13C.
[0041] FIGS. 14-16 are perspective views of mailpieces in accordance with
alternative
embodiments of the invention.
[0042] FIG. 17 is a partial perspective view of a mailpiece in accordance with
an
embodiment of the invention.
[0043] FIG. 18 is a partial perspective view of a portion of a mailpiece in
accordance
with an embodiment of the invention.
[0044] FIG. 19 is a partial perspective view of a mailpiece in accordance with
an
alternative embodiment of the invention.
[0045] FIG. 20 is a cross-sectional view of the mailpiece of FIG. 19 with the
frangible
article and spacer inserted into the mailpiece.
[0046] FIG. 20A is an enlarged cross-sectional view of a portion of FIG. 19.
[0047] FIG. 20B is an enlarged partial cross-sectional view similar to FIG.
20A of a
mailpiece in accordance with an alternative embodiment.
[0048] FIG. 20C is an enlarged partial cross-sectional view similar to FIGS.
20A and
20B of a mailpiece in accordance with an alternative embodiment.
[0049] FIG. 21A is an end cross-sectional view of the mailpiece of FIGS. 20
and 20A
held by belts and being transported past a crown roller.
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[0050] FIG. 21 B is an end cross-sectional view similar to FIG. 21 A with the
opposite
panel of the mailpiece riding over a crown roller.
[0051] FIG. 22A is a perspective view of a frangible article in accordance
with an
embodiment of the invention.
[0052] FIG. 22B is a partial end cross-sectional view of the frangible article
of FIG. 22A.
Detailed Description
[0053] With reference to FIG. 4 in which like reference numerals refer to like
features in
FIGS. 1-3 and in accordance with an embodiment of the invention, a mailpiece
23, which is
similar in most respects to mailpiece 22, includes spacers 38a, 40a disposed
above contact point
24 and spacers 38b, 40b that are disposed below contact point 24. The spacers
38a,b and 40a,b
are aligned generally parallel to the peripheral edges 46, 48.
[0054] Spacers 38a and 38b are spaced vertically along the height, h, of the
mailpiece 23
relative to contact point 24, as are spacers 40a and 40b. The article 16,
spacers 38a,b, and
spacers 40a,b are positioned within the mailpiece 23 such that the
circumference 26 of the
crowned roller 12 (and, thus, the linear path traced by contact point 24
across the length, L, of
the mailpiece 23 between lateral edges 50, 52 (FIG. 7)) is between spacers 38a
and 38b and is
also between spacers 40a and 40b. Typically, spacers 38a, 40a and spacers 38b,
40b are
positioned within mailpiece 23 such that the central axis 19 of the article 16
is located between
spacers 38a, 40a and spacers 38b, 40b. However, the precise location of the
central axis 19 of
the article 16 relative to spacers 38a, 40a and spacers 38b, 40b is contingent
upon the positioning
of the article 16 inside the mailpiece 23 and the location of the spacers 38a,
40a and spacers 38b,
40b. Accordingly, the article 16 may be positioned inside the mailpiece 23 to
optimize the
effectiveness of the spacers 38a,b, 40a,b in view of all mailpiece design
parameters. For
example, inserts or a pocket (not shown) may be used to position the article
16 inside the
mailpiece 23 to optimize the effective of the spacers 38a,b, 40a,b. Spacer 38a
may be collinear
or non-collinear with spacer 40a. Similarly, spacer 38b may be collinear or
non-collinear with
spacer 40b.
[0055] Spacers 38a,b, and spacers 40a,b have a thickness, tl, measured
relative to the
thickness, w, of the mailpiece 23 that is selected to keep the frangible
article 16 from being
forced to conform to the vertically convex (i.e. crowned) surface 13 of the
roller 12, as well as
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those of other rollers, drums, spindles or mechanical apparatus (not shown)
used in postal
processing equipment. Spacers 38a,b, and spacers 40a,b locally increase the
thickness of
mailpiece 23 and represent a minor deviation from planarity of the side
surfaces of panels 42, 44
nearest to the article 16. The respective thicknesses, tl, of the spacers
38a,b, and spacers 40a,b is
suitably chosen to provide the amount of filler required to at least partially
bridge one or both of
the gaps 32a, 32b (FIG. 2A). This reduces the bending or conforming of the
article 16 relative to
the crowned surface 13 of the roller 12 and along the height of the roller 12.
In certain
embodiments, the curvature of the crown on roller 12 is slight so that the
spacers 38a,b, and
spacers 40a,b may be relatively thin, such as, for example, the thickness of
two or three sheets of
folded paper, or in the range of about 1/16" to about 1/32".
[0056] Spacers 38a,b are disposed between one side of article 16 and panel 44.
Spacers
40a,b are disposed between the opposite side of the article 16 and pane142.
Article 16 is
disposed between spacers 38a and 40a, which are positioned within the
mailpiece 23 and relative
to article 16 such that the portion of panel 42 adjacent to spacer 40a
contacts the roller 12
between the peripheral rim 30a and contact point 24 on the circumference 26.
Spacers 38b and
40b are positioned within the mailpiece 23 and relative to article 16 such
that the portion of panel
42 adjacent to spacer 40b contacts the bottom of roller 12 between the
peripheral rim 30b and
contact point 24 on the circumference 26.
[0057] Spacers 38a,b operate to reduce the amount of flexing of the article 16
because of
the tendency of the mailpiece 23 to conform to the crowned surface 13 of the
roller 12. Thus, in
the arrangement depicted in FIG. 4, the surface 13 of the roller 12 contacts
the side surface of
panel 42, while the surface 13 of the roller 12 may contact the side surface
of panel 44 if the
mailpiece 23 were oriented on the opposite side of the roller 12 (such
orientation not shown but
similar to FIGS. 5A,B). Positioning of one or more of spacers 38a,b, 40a,b on
each side of the
article 16 ensures that the article 16 will be protected against excessive
bending regardless of
whether or not edge 46 is the top or bottom edge, and regardless of whether
pane142 or pane144
is in contact with the roller 12.
[0058] The design of the mailpiece 23 and the requirements for effectively
limiting the
amount of bending and flexing of the article 16 may determine the number of
spacers 38a,b,
40a,b. In certain embodiments, fewer than all of the multiple spacers 38a,b,
40a,b may be
required. Spacers 38a,b, 40a,b may be contained within the plane of the
mailpiece 23 or may
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project as short asperities (e.g., parallel ridges) from the opposite sides of
the mailpiece 23 and
inwardly toward the article 16 inside the mailpiece 23.
[0059] The mailpiece 23 may conform to the shape of the crowned surface 13 on
the
crowned roller 12 between the spacers 38a and 38b, if the exposed side of
panel 44 contacts the
roller 12, or between spacers 40a and 40b, if pane142 contacts the roller 12.
The spacers 38a,b,
40a,b are shaped and have a thickness, ti, sufficient to mitigate the effect
of the curvature in the
crowned roller 12 or other crown-profiled belt support members that may be
used for proper
carriage and tracking of drive belts (not shown) in mail or postal processing
equipment. By
keeping the article 16 from being forced to conform to the convex shape of the
crowned roller 12
along the height, h, of the mailpiece 23 at the same time the article 16 is
bending about the
circumference 26 of the roller 12, damage to the article 16 may be eliminated
or, at the least, the
probability is reduced that article 16 will be damaged by the effect of
conforming to the surface
13 of roller 12.
[0060] Spacers 38a,b, 40a,b may be sized and shaped to orient the frangible
article 16
substantially parallel to a tangent plane 36 when pressure 28 is exerted.
Spacers 38a,b, 40a,b
may be integrally formed or attached to a mailpiece such as mailpiece 23 or
may alternatively be
made part of a sleeve or similar device holding the article 16 such that the
sleeve or similar
device is placed inside a mailpiece 23 for mailing. Likewise, spacers 38a,b,
40a,b may
alternatively be made part of or be attached to the article 16 prior to being
inserted into a
mailpiece 23.
[0061] Spacers 38a,b, 40a,b may be rigid and non-compressible, such that no
deformation occurs under the influence of the belt pressure 28 and thickness,
ti, is maintained.
Alternatively, the spacers 38a,b, 40a,b may be substantially rigid, such that
negligible
deformation occurs under the influence of the belt pressure 28 and thickness,
tl, is substantially
maintained. In an alternative embodiment, if the spacers 38a,b, 40a,b are non-
rigid, their
thickness is chosen to compensate for any deformation that occurs under the
influence of the belt
pressure 28 such that the compressed thickness, tl, is sufficient to mitigate
the flexing. Any
cushioning effect provided by the spacers 38a,b, 40a,b is incidental to the
mitigation of the
flexing of the article 16.
[0062] With reference to FIGS. 5A and 5B in which like reference numerals
refer to like
features in FIGS. 1-4 and in accordance with an alternative embodiment of the
invention, a
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generally rectangular mailpiece 54, which is similar in most respects to
mailpiece 22, includes
two spacers 37a,b that separate the article 16 from the panels 42, 44. In this
embodiment,
spacers 37a,b are sized and positioned within mailpiece 54 in such a manner as
to engage roller
12 providing a straight surface against which article 16 will be pressed when
the belt pressure 28
is exerted on the article 16. As a result, bending of the article 16 in
accordance with the crowned
surface 13 of the roller 12 is limited, which mitigates the flexure of the
article 16.
[0063] Spacers 37a,b may be integrally formed or attached to mailpiece 54 or
may
alternatively be made part of a sleeve or similar device holding the article
16 such that the sleeve
or similar device is placed inside a mailpiece such as the conventional
mailpiece 22 (FIGS. 1-3)
for mailing. Likewise, spacers 37a,b may alternatively be made part of, or may
be attached to,
the frangible article 16 prior to being inserted into a mailpiece. The
materials and dimensions of
spacers 37a,b may be suitable chosen to limit bending of article 16. Spacers
37a,b may, for
example, comprise a thickness, t2, measured in the same direction as the
width, w2, of mailpiece
54 that is larger, smaller or equal to the width, w2. The thickness, t2, of
spacers 37a,b may
greater than the thickness, tl, of spacers 38a,b, 40a,b (FIG. 4).
[0064] Spacers 37a,b may be rigid and non-compressible, such that no
deformation
occurs under the influence of the belt pressure 28. Alternatively, the spacers
37a,b may be
substantially rigid, such that negligible deformation occurs under the
influence of the belt
pressure 28 and thickness, t2, is substantially maintained. In an alternative
embodiment, if the
spacers 37a,b are non-rigid, their thickness is chosen to compensate for any
deformation that
occurs under the influence of the belt pressure 28 such that the compressed
thickness, t2, is
sufficient to mitigate the flexing. Any cushioning effect provided by the
spacers 38a,b, 40a,b is
incidental to the mitigation of the flexing of the article 16.
[0065] Typically, the central axis 19 of the article 16 is located between
spacers 37a,b.
However, the precise location of the central axis 19 of the article 16
relative to spacers 37a,b is
contingent upon the positioning of the article 16 inside the mailpiece 23 and
the positioning of
the spacers 37a,b inside the mailpiece 23. Accordingly, the article 16 may be
positioned inside
the mailpiece 23 to optimize the effectiveness of the spacers 37a,b in view of
all mailpiece
design parameters. For example, inserts or a pocket (not shown) may be used to
position the
article 16 inside the mailpiece 23 to optimize the effective of the spacers
37a,b.
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CA 02591364 2007-06-05
[0066] With specific reference to FIG. 5A, the belt pressure 28 on the
mailpiece 54 and
the article 16 will result in the article 16 being tilted such that article 16
is pushed against a
portion of panel 42 between the rim 30a and contact point 24 of the roller 12
and against spacer
37b. This force profile is such that the bending or flexure of the article 16
along the height, h, of
the mailpiece 54 is reduced, or eliminated, as mailpiece 54 is transported
past the roller 12.
[0067] With specific reference to FIG. 5B, the mailpiece 54 rides over the
surface of
roller 12 with an outer surface of the opposite panel 44 riding against the
surface 13. The belt
pressure 28 on the mailpiece 54 and the article 16 will result in the article
16 and mailpiece 54
being tilted such that article 16 is pushed against a portion of pane144
between the rim 30b and
circumference 26 of the roller 12 and against spacer 37a. This force profile
is such that there is
reduced bending or flexure of the article 16 along the height, h, of the
mailpiece 54 as mailpiece
54 is transported past the roller 12.
[0068] With reference to FIG. 6 in which like reference numerals refer to like
features in
FIGS. 1-5 and in accordance with an alternative embodiment of the invention, a
generally
rectangular mailpiece 64, which is similar in most respects to mailpiece 22,
includes a pair of
spacers 37c,d on the same side of the contact point 24. The position of the
spacers 37c,d may be
adjusted so that they lie either above or below contact point 24. The spacers
37c,d are sized,
including a thickness, t3, and positioned in such a manner as to engage roller
12 providing a
straight surface against which article 16 will be pressed when the belt
pressure 28 is applied to
the article 16. Accordingly, the article 16 may be positioned inside the
mailpiece 23 to optimize
the effectiveness of the spacers 37c,d in view of all mailpiece design
parameters. For example,
inserts or a pocket (not shown) may be used to position the article 16 inside
the mailpiece 23 to
optimize the effective of the spacers 37c,d. The spacers 37c,d, thereby limit
bending of the
article 16 about the crowned surface 13 of the roller 12 along the height, h,
of the mailpiece 64.
[0069] The belt pressure 28 exerted on the mailpiece 64 and the article 16
will result in
the article 16 and mailpiece 64 being canted or tilted such that article 16 is
pushed against a
portion of the mailpiece pane142 between the rim 30b and contact point 24 of
the roller 12 and
against spacer 37d. This force profile is such that bending or flexure of the
article 16 is reduced
as it rides over the surface 13 of the roller 12. While the embodiment of FIG.
6 depicts
mailpiece 64 oriented such that pane142 rides against the surface 13 of the
roller 12, mailpiece
64 would be similarly suitably adapted to be oriented such that panel 44 rides
against the surface
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CA 02591364 2007-06-05
13 of the roller 12. In this case, the belt pressure 28 would result in the
article 16 and mailpiece
64 being tilted such that article 16 is pushed against a portion of the
mailpiece panel 44 between
the rim 30b and contact point 24 of the roller 12 and against spacer 37c. The
resulting force
profile would be such that bending or flexure of the article 16 is reduced as
the mailpiece 64 is
transported across the surface 13 of the roller 12.
[0070] Spacers 37c,d and article 16 are located in the mailpiece 64 such that
the spacers
37c,d are disposed between the article 16 and roller 12. Spacers 37c,d may be
rigid and non-
compressible, such that no deformation occurs under the influence of the belt
pressure 28.
Alternatively, the spacers 37c,d may be substantially rigid, such that
negligible deformation
occurs under the influence of the belt pressure 28 and thickness, t3, is
substantially maintained.
In an alternative embodiment, if the spacers 37c,d are non-rigid, their
thickness is chosen to
compensate for any deformation that occurs under the influence of the belt
pressure 28 such that
the compressed thickness, t3, is sufficient to mitigate the flexing. Any
cushioning effect
provided by the spacers 37c,d is incidental to the mitigation of the flexing
of the article 16.
[0071] With reference to FIGS. 7-12, in which like reference numerals refer to
like
features in FIGS. 4-6, various exemplary embodiments of mailpieces in
accordance with the
principles of the invention are shown.
[0072] With reference to FIGS. 7, 7A, and 8 in which like reference numerals
refer to
like features in FIGS. 1-6 and in accordance with an alternative embodiment of
the invention, a
mailpiece 23a includes spacers 60a-c arranged in a configuration similar to
spacers 38a,b, 40a,b
(FIG. 4). Spacers 60a,b each comprise a respective elongated member 61 a,b
secured by securing
members 63a,b, respectively, with the inner surface of pane142 of mailpiece
23a. Spacers 60c,d
each comprise a respective elongated member 61c,d secured by securing members
63c,d,
respectively, with the inner surface of panel 44 of mailpiece 23a. Elongated
members 63a-d may
have a length substantially equal to the length, L, of the mailpiece 23a, and
may extend between
the lateral edges 50, 52, although the invention is not so limited. Securing
members 63a-d may
each include adhesive portions at least in the areas that contact the inner
surface of the respective
one of the panels 42, 44. Alternatively, other suitable bonding methods or
components such as,
for example, thermal-bonding components or mechanical stitching, may be
substituted instead of
securing members 63a-d for securing the elongated members 61a-d with the inner
surface of the
respective panels 42, 44.
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CA 02591364 2007-06-05
[0073] When belt pressure 28 (FIG. 4) is applied, the behavior of mailpiece
23a and
article 16 is similar to that described in the embodiment of FIG. 4, which
shows the general
principles for the behavior of maiipieces with this type of spacer
configuration. A person having
ordinary skill in the art will appreciate that elongated members 61a-d and
securing members 63a-
d may have any other length relative to the length, L, of mailpiece 23a, or
may alternatively have
different lengths with respect to each other. In an alternative embodiment,
the invention
contemplates that mailpiece 23a may include only spacers 60a, 60d (or 60b,
60c) arranged in
compliance with the arrangement of spacers 37a,b (FIGS. 5A,B). In another
alternative
embodiment, the invention contemplates that mailpiece 23a may include only
spacers 60a,c (or
60b,d) arranged in compliance with the arrangement of spacers 37c,d (FIG. 6).
[0074] Mailpiece 23a may further include a flap 56 integrally formed with
panel 42 along
a fold line 47 and adjoining an opening 43 into the space between panels 42,
44. The flap 56 has
an adhesive region 58 suitable to adhere flap 56 to the outer surface of
pane144 or, alternatively,
any other non-adhesive coupling components suitable to couple the two involved
surfaces. A
person having ordinary skill in the art will appreciate that the flap 56 may
be characterized by a
different shape, size, material, and/or relative location on mailpiece 23a.
Alternatively, the flap
56 may be omitted from the construction of mailpiece 23a.
[0075] With reference to FIG. 9 in which like reference numerals refer to like
features in
FIGS. 1-8 and in accordance with an alternative embodiment of the invention, a
mailpiece 23b
has spacers 68 (of which only a portion of one spacer 68 is shown for
illustrative purposes)
consisting of elongated adhesive beads bonded, adhered, or otherwise coupled
to the inner
surface of, for example, pane142. The spacers 68 may made of any other
material suitable to be
coupled to the inner surfaces of the panels 42, 44, such as hot melt
adhesives, cohesives,
caulking materials, and the like. Spacers 68 may have a length substantially
equal to the length,
L, of mailpiece 23b and substantially extending between lateral edges 50,52.
Alternatively,
spacers 68 may be of any relative length and location with respect to the
mailpiece 23b and have
any non-tubular geometry or even an irregular cross-section effective to
mitigate the flexing of
the article 16.
[0076] In one embodiment, the spacers 68 may be arranged on panels 42, 44 of
mailpiece
23b in compliance with the arrangement of spacers 38a,b, 40a,b (FIG. 4) or
spacers 60a,b, 60c,d
(FIG. 8). In an alternative embodiment, the invention contemplates that
spacers 68 may be
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CA 02591364 2007-06-05
arranged on panels 42, 44 of mailpiece 23b in compliance with the arrangement
of spacers 37a,b
(FIGS. 5A,B). In another alteinative embodiment, the invention contemplates
that the spacers 68
may be arranged on panels 42, 44 of mailpiece 23b in compliance with the
arrangement of
spacers 37c,d (FIG. 6).
[0077] With reference to FIG. 10 in which like reference numerals refer to
like features
in FIGS. 1-9 and in accordance with an alternative embodiment of the
invention, a mailpiece 23c
includes a plurality of spacers 70 (only a portion of one row of spacers 70 is
shown for
illustrative purposes), each of a length substantially smaller than the
length, L, (FIG. 7) of
mailpiece 23c, positioned in series (e.g., a row) such that their cumulative
end-to-end length may
substantially extend between lateral edges 50, 52 (FIGS. 7, 10). Spacer 70
comprises a staple-
like structure made of deformable metal, plastic, or any other suitable
material, having a general
U-shape and including a main portion 70a and two opposed leg members 70b
extending from the
ends of main portion 70a. Each of the spacers 70 is adapted to deform between
an open position
and a closed position coupled with a respective one of the panels 42, 44.
Spacer 70 engages the
inner surface of, for example, panel 42 in the direction shown by arrows 71,
such that the leg
members 70b fold behind the opposite, outer surface of each panel, as depicted
by spacer 70'.
While this embodiment describes serially positioned spacers 70 extending
substantially along the
entire length, L, of mailpiece 23c, persons of ordinary skill in the art will
appreciate that spacers
70 may be of any relative length and location with respect to the mailpiece
23c and have any
cross-sectional shape effective to mitigate the flexing of the article 16.
[0078] In one embodiment, the spacers 70 of mailpiece 23c may be arranged on
panels
42, 44 of mailpiece 23c in compliance with the arrangement of spacers 3 8a,b,
40a,b (FIG. 4) or
spacers 60a,b, 60c,d (FIG. 8). In an alternative embodiment, the invention
contemplates that
spacers 70 may be arranged on panels 42, 44 of mailpiece 23c in compliance
with the
arrangement of spacers 37a,b (FIGS. 5A,B). In another alternative embodiment,
the invention
contemplates that spacers 70 may be arranged on panels 42, 44 of mailpiece 23c
in compliance
with the arrangement of spacers 37c,d (FIG. 6).
[0079] With reference to FIG. 11 in which like reference numerals refer to
like features
in FIGS. 1-10 and in accordance with an alternative embodiment of the
invention, a mailpiece
23d includes spacers 72 (only a portion of one spacer 72 is shown for
illustrative purposes) of a
length substantially equal to the length, L, (FIG. 7) of mailpiece 23d, and
substantially extending
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CA 02591364 2007-06-05
between lateral edges 50, 52 (FIGS. 7, 11). Spacer 72 comprises a Z-folded
section 73 of, for
example, panel 42 that locally increases the relative thickness of pane142. A
securing member
74 may be applied over the Z-folded section 73 to secure the fold in place and
prevent unfolding.
Securing member 74, having a length substantially equal to that of the Z-
folded section 73, may
have adhesive portions (not shown) or other suitable coupling components such
as, for example,
mechanical, thermal or chemical components to secure it against the inner
surface of each panel.
Alternatively, Z-folded sections 73 may include adhesive portions allowing it
to retain the fold(s)
in place without the need for securing members 74.
[0080] In one embodiment, the spacers 72 may be arranged on panels 42, 44 of
mailpiece
23d in compliance with the arrangement of spacers 38a,b, 40a,b (FIG. 4) or
spacers 60a,b, 60c,d
(FIG. 8). In an alternative embodiment, the invention contemplates that
spacers 72 may arranged
on panels 42, 44 of mailpiece 23d to comply with the arrangement of spacers
37a,b (FIGS.
5A,B). In another alternative embodiment, the invention contemplates that
spacers 72 may be
arranged on panels 42, 44 of mailpiece 23d in compliance with the arrangement
of spacers 37c,d
(FIG. 6).
[0081] While the embodiment of FIG. 11 depicts and describes Z-folded sections
73 and
securing members 74 of respective lengths substantially equal to length, L, of
mailpiece 23d,
persons of ordinary skill in the art will appreciate that the folded sections
may adopt a different
non-Z-shape folded configuration effective to mitigate the flexing of the
article 16. Likewise, Z-
folded sections 73 and securing members 74 may have any other length relative
to the length, L,
of mailpiece 23d, or may alternatively have different lengths with respect to
each other effective
to mitigate the flexing of the article 16.
[0082] With reference to FIG. 12 in which like reference numerals refer to
like features
in FIGS. 1-11 and in accordance with an alternative embodiment of the
invention, a mailpiece
23e includes spacers 76 (only one spacer 76 is shown for illustrative
purposes) of a length
substantially equal to the length, L, (FIG. 7) of mailpiece 23e, and
substantially extending
between lateral edges 50, 52 (FIGS. 7, 12). Spacer 76 may, for example,
comprise a stack of
laminated flat members 78, 78', 78" coupled to the inner surface of, for
example, pane142. The
flat members 78, 78', 78" increases the local relative thickness of pane142 in
that particular
section, thereby creating an effective spacer 76 on pane142. Flat members 78,
78', 78" may be
made of the same or different substrates, have equal or unequal respective
lengths, and have
-17-
CA 02591364 2007-06-05
adhesive portions (not shown) or other suitable coupling components such as,
for example,
mechanical, thermal or chemical components to permit coupling with adjacent
flat rectangular
members or the inner surface of a panel. Flat rectangular members 78, 78', 78"
may be, for
example, made of the same substrate, have equal lengths and each have adhesive
portions on one
the respective sides.
[0083] While the embodiment of FIG. 12 depicts and describes spacers 76
comprising
flat members 78, 78', 78", persons of ordinary skill in the art will
appreciate that the flat
members 78, 78', 78" may adopt a different shape than rectangular. Alternate
shapes for the flat
members 78, 78', 78" may, for example, include square, round, oval, triangular
or polygonal
members in any number and of any suitable dimensions and thickness effective
to mitigate the
flexing of the article 16. Likewise, flat, members 78, 78', 78" may have any
other length relative
to the length, L, of mailpiece 23e effective to mitigate the flexing of the
article 16.
[0084] In one embodiment, the spacers 76 may be arranged on panels 42, 44 of
mailpiece
23e in compliance with the arrangement of spacers 38a,b, 40a,b (FIG. 4) or
spacers 60a,b, 60c,d
(FIG. 8). In an alternative embodiment, the invention contemplates that
spacers 76 may arranged
on panels 42, 44 of mailpiece 23e in compliance with the arrangement of
spacers 37a,b (FIGS.
5A,B). In another alternative embodiment, the invention contemplates that
spacers 76 may be
arranged on panels 42, 44 of mailpiece 23e in compliance with the arrangement
of spacers 37c,d
(FIG. 6).
[0085] Embodiments of the invention contemplate that the spacers may be
carried on a
separate sleeve that is inserted into the mailpiece, as opposed to spacers
directly carried by the
mailpiece. The spacers may also comprise an insert that is loosely placed
inside a mailpiece.
The invention contemplates that the sleeve or insert(s) may include any of the
spacer structures
described above in connection with FIGS. 7-12 for mitigating or reducing the
stress applied to
the article when the belt pressure causes the mailpiece and the sleeve or
insert to conform to the
curved shape of the crown of a crowned roller.
[0086] With reference to FIGS. 13A,B in which like reference numerals refer to
like
features in FIG. 7 and in accordance with an alternative embodiment of the
invention, a
mailpiece 23g, which is otherwise similar in most respects to mailpiece 23a
(FIG. 7), includes a
sleeve 84 adapted to hold the frangible article 16. Sleeve 84 is configured
with spacers in the
form of a series of semi-circular foldable flaps 94a,b folded against the
respective back surfaces
-18-
CA 02591364 2007-06-05
. = ,.
of each panel 85, 87 in respective directions indicated by arrows 95a, 95b.
The flaps 94a,b
effectively increase the local thickness of the sleeve 84.
[0087] Sleeve 84 may be a generally rectangular or square assembly formed of
two
opposed panels 85, 87, having top and bottom peripheral edges 90, 92, and
lateral or side edges
86, 88. Bottom edge 92 may be folded to contact the outer side of panel 85,
thereby enclosing
the sleeve 84 and containing article 16. The folded section along bottom edge
92 may or may
not have adhesive, or other suitable coupling components, permitting coupling
with the outer
side of panel 85. Alternatively, the folded section along the bottom edge 92
may be omitted.
[0088] The flaps 94a,b originate from semi-circular apertures 93a,b punched
through the
constituent material of sleeve 84. The apertures 93a,b are formed at selected
locations on each of
the panels 85, 87 so that the flaps 94a,b comply with the arrangement of
spacers 37a,b (FIGS.
5A,B). Apertures 93a,b and flaps 94a,b may be generally aligned in a direction
parallel to top
and bottom edges 90, 92 of sleeve 84, such that a first set of flaps 94a may
be adapted to lie on
pane185 either above or below the central axis 19 of article 16, while a
second set of flaps 94b
may be adapted to lie on panel 87 on the opposite side (i.e. above or below)
of central axis 19 of
article 16. In the exemplary embodiment of FIGS. 13A,B, the first set of flaps
94a from
apertures 93a on panel 85 lies below central axis 19 of article 16 and the
second set of flaps from
apertures 93b on panel 871ies above central axis 19 of article 16.
Alternatively, the first set of
flaps 94b on panel 85 may lie above central axis 19 of article 16 while the
second set of flaps 94a
on panel 87 may lie below central axis 19 of article 16, which is in
compliance with the
arrangement of spacers 37c,d (FIG. 6).
[0089] While sleeve 84 is depicted having two sets of flaps 94a,b from three
semi-
circular apertures 93a,b, persons of ordinary skill in the art will appreciate
that sleeve 84 may
alternatively, comprise any other number of flaps and apertures of any
suitable shape (other than
semi-circular), such as square, rectangular, triangular, oval or polygonal.
[0090] Article 16 may be placed within sleeve 84, which may in turn be
inserted into
mailpiece 23g in the direction indicated by arrow 98, thereby defining the
configuration of the
general embodiment depicted in FIGS. 5A,B. Upon application of belt pressure
28, the
mailpiece 23g and article 16 behave similar to the behavior described with
regard to the
embodiment of FIGS. 5A,B. The sleeve 84 is located inside the mailpiece 23g,
the flaps 94a,b
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CA 02591364 2007-06-05
are located on the sleeve 84, and the article 16 is located inside the sleeve
84 such that the flaps
94a,b intervene between the article 16 and roller 12.
[0091] With reference to FIGS. 13C,D in which like reference numerals refer to
like
features in FIGS. 13A, B and in accordance with an alternative embodiment of
the invention, a
sleeve 100, which is otherwise similar to sleeve 84, includes spacers in the
form of round
members 102 coupled with the apertures 93c,d. The sleeve 100 replaces sleeve
84 (FIGS.
13A,B) in mailpiece 23g. The apertures 93c,d and round members 102 are aligned
in a direction
generally parallel to top and bottom edges 90, 92 of sleeve 100. Apertures 93c
are adapted to lie
on panel 85 either above or below the central axis 19 of article 16. Apertures
93d are adapted to
lie on panel 87 on the opposite side of central axis 19. The first set of
apertures 93c round
members 102 on panel 85 lies below central axis 19 of article 16 and the
second set of apertures
93d and round members 102 on panel 871ies above central axis 19 of article 16.
Alternatively,
the first set of apertures 93c and round members 102 on pane185 may lie above
central axis 19
of article 16 while the second set of apertures 93d on panel 87 and round
members 102 may lie
below central axis 19 of article 16. While apertures 93c,d are depicted having
a generally square
or rectangular shape, persons of ordinary skill in the art will appreciate
that apertures 93a,b may
have any suitable shape so long as such shape includes at least one straight
edge.
[0092] Round members 102 are folded and coupled about a straight edge of each
aperture
93c,d such that, when folded against the respective back surfaces of each
panel 85, 87, they
effectively increase the thickness of the sleeve 100 in the portions including
the round members
102, thereby defining spacers similar to spacers 37a,b (FIGS. 5A,B). Round
members 102 may
be made, for example, of paper, cardboard, plastic, rubber, or other materials
of suitable
thickness. Round members 102 may be adhesively bonded with the surfaces of
panels 85, 87 or
may be coupled therewith in a different manner.
[0093] While sleeve 100 is depicted having two sets of apertures 93a, persons
of ordinary
skill in the art will appreciate that sleeve 100 may, alternatively, comprise
any other number of
apertures of any suitable shape (other than square) such as rectangular,
triangular, oval or
polygonal. Sleeve 100 is depicted having two rows of diametrically opposed
(with respect to
central axis 19 of article 16) apertures 93a, thus attaining the arrangement
of spacers 37a,b
(FIGS. 5A,B). However, sleeve 100 may alternatively comprise two confronting
sets of
apertures 93a lying on the same side (i.e. above or below) of central axis 19,
thereby attaining the
-20-
CA 02591364 2007-06-05
arrangement of spacers 37c,d (FIG. 6). Similarly, round members 102 may be
replaced with
members of any other shape suitable to be coupled about an edge or portion of
apertures 93a,
which may alternatively be a slit instead of an aperture.
[0094] Article 16 may be placed within sleeve 100, which may in turn be
inserted into
mailpiece 23g (FIG. 13A). Upon application of belt pressure 28, the behavior
of the mailpiece
23g, sleeve 100, and article 16 is similar to that described in the embodiment
of FIGS. 5A,B. The
sleeve 100 is located inside the mailpiece 23g, the round members 102 and
apertures 93c,d are
located on the sleeve 100, and the article 16 is located inside the sleeve 100
such that the round
members 102 intervene between the article 16 and roller 12.
[0095] With reference to FIG. 14 in which like reference numerals refer to
like features
in FIG. 13A and in accordance with an alternative embodiment of the invention,
a generally
rectangular sleeve 104, which is similar to sleeve 84 (FIGS. 13A,B) and sleeve
100 (FIGS.
13C,D), includes a series of spacers in the form of projections or disks
105a,b are coupled to
respective inner surfaces of the panels 85, 87 at selected locations so as to
meet the spacer
configuration of the general embodiment of FIGS. 5A,B. The sleeve 104 is
folded in the
direction indicated by arrow 114 to thereby enclose frangible article 16. The
sleeve 104 may
replace sleeve 84 (FIGS. 13A,B) in mailpiece 23g (FIGS. 13A,B).
[0096] Disks 105a,b may be aligned in a direction generally parallel to top
and bottom
edges 90, 92 of sleeve 104, such that a first set of disks 105a,b is coupled
to pane185 either
above or below the central axis 19 of article 16, while a second set of disks
105a,b is coupled to
pane187 on the opposite side of central axis 19. In the exemplary embodiment
of FIG. 14, a first
set of three disks 105b on panel 85 lie below central axis 19 of article 16
while a second set of
three disks 105a on pane187 lie above central axis 19 of article 16.
Alternatively, the first set of
disks 105b on panel 85 may lie above central axis 19 while the second set of
disks 105a on panel
87 may lie below central axis 19.
[0097] Disks 105a,b, which project from the plane of the corresponding panel
85, 87,
effectively increase the local thickness of the sleeve 100. As a result, the
disks 105a,b thereby
define spacers with an arrangement similar to spacers 37a,b (FIGS. 5A,B). In
an alternative
embodiment, the disks 105a,b and another pair of similar disks (not shown) may
be arranged in
compliance with the arrangement of spacers 38a,b, 40a,b (FIG. 4) or spacers
60a,b, 60c,d (FIG.
8). In another alternative embodiment, the invention contemplates that disks
105a,b may be
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CA 02591364 2007-06-05
arranged in compliance with the arrangement of spacers 37c,d (FIG. 6). While
sleeve 104 is
depicted having two rows of circular disks 105a,b of three, persons of
ordinary skill in the art
will appreciate that sleeve 104 may alternatively comprise any other number of
circular disks
105a,b of any suitable size and shape (circular or non-circular), such as
square, rectangular,
triangular, oval or polygonal.
[0098] Disks 105a,b may be made of any suitable material such as rubber,
plastic,
cardboard, paper, film or any other type of substrate and may have a thickness
in accordance
with the amount of bending to which article 16 would otherwise be exposed.
Disks 105a,b may
be constructed from a non-rigid material, such as a cellular foam, with a
thickness chosen to
compensate for any deformation or compression that occurs under the influence
of the belt
pressure 28 (FIG. 2) such that the compressed thickness is sufficient to
mitigate the flexing of
article 16.
[0099] Disks 105a,b may be adhesively bonded to the respective inner surfaces
of panels
85, 87 of sleeve 104. Alternatively, other suitable coupling components may be
included to
secure disks 105a,b on the surface of panels 85, 87 or alternatively disks
105a,b may be
integrally formed with panels 85, 87. Disks 105a,b may alternatively comprise
pockets filled
with a fluid either injected into the panels 85, 87 or created by layering or
laminating multiple
sheets to form panels 85, 87.
[00100] Article 16 may be placed within sleeve 104, which may in turn be
inserted into
mailpiece 23g (FIGS. 13A,B), thereby defining the configuration of the general
embodiment
depicted in FIGS. 5A,B. Upon application of pressure against the belts 11
(FIGS. 5A,B), the
behavior of the mailpiece, sleeve 104 and article 16 is similar to that
described in the
embodiment of FIGS. 5A,B, showing the general principles of the behavior of
mailpieces having
spacers with this type of configuration. The sleeve 104 is located inside the
mailpiece 23g, the
disks 105a,b are located on the sleeve 104, and the article 16 is located
inside the sleeve 104 such
that the disks 105a,b intervene between the article 16 and roller 12.
[00101] With reference to FIG. 15 in which like reference numerals refer to
like features
in FIG. 13A and in accordance with an alternative embodiment of the invention,
mailpiece 23g
(FIG. 13A) may include a sleeve 108 adapted to receive frangible article 16.
The sleeve 108
replaces sleeve 84 (FIGS. 13A,B) in mailpiece 23g. Circular spacers 110a,b may
be disposed at
selected locations on panel 87 and circular spacers 112a,b may be disposed at
selected locations
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CA 02591364 2007-06-05
on panel 85 so as to comply with the configuration of the general embodiment
of FIG. 4. A first
pair of diametrically opposed circular spacers 110a, b may lie on panel 87
while a second pair of
diametrically opposed circular members 112a,b may lie on panel 85. When sleeve
108 is formed
by bringing panels 85,87 together in the direction indicated by arrow 114, a
pair of facing
circular spacers I 10a, 112a may lie on one side (i.e. above or below) of
central axis 19 of article
16, while a second pair of facing circular spacers 110b, 112b may lie on the
opposite side of
central axis 19. Circular spacers 110a,b, 112a,b effectively increase the
thickness of the sleeve
108 in the portions including the spacers 1 I Oa,b, 112a,b, thereby defining
spacers similar to
spacers 38a,b, 40a,b (FIG. 4) or spacers 60a,b, 60c,d (FIG. 8).
[00102] In an alternative embodiment, the invention contemplates that one of
the spacers
110a,b and one of the spacers 112a,b may arranged to comply with the
arrangement of spacers
37a,b (FIGS. 5A,B). In another alternative embodiment, the invention
contemplates that one pair
of the spacers 110a,b, 112a,b may be omitted to provide an arrangement in
compliance with the
arrangement of spacers 37c,d (FIG. 6). While sleeve 108 is depicted having two
pairs of circular
spacers 110a,b, 112a,b, persons of ordinary skill in the art will appreciate
that sleeve 108 may
alternatively comprise any other number of pairs of spacers of any suitable
size or shape (other
than circular), such as square, rectangular, triangular, oval or polygonal.
[00103] Article 16 may be placed within sleeve 108, which may in turn be
inserted into
mailpiece 23g (FIGS. 13A,B), thereby defining the configuration of the general
embodiment
depicted in FIG. 4. Upon application of pressure 28 against the belts 11 (FIG.
4), the behavior of
the mailpiece and article 16 is similar to that described in the embodiment of
FIG. 4, showing the
general principles of the behavior of mailpieces having spacers with this type
of configuration.
The sleeve 108 is located inside the mailpiece 23g, the 1 l0a,b, 112a are
located on the sleeve
108, and the article 16 is located inside the sleeve 108 such that the 110a,b,
112a intervene
between the article 16 and roller 12.
[00104] The invention contemplates that the mailpiece itself, rather than a
sleeve inserted
into a mailpiece, may include any of the spacer structures described above in
connection with
FIGS. 14 and 15 for mitigating or reducing the stress applied to the article
when the belt pressure
causes the mailpiece to conform to the curved shape of the crown of a crowned
roller.
[00105] With reference to FIG. 16 in which like reference numerals refer to
like features
in FIG. 7 and in accordance with an alternative embodiment of the invention, a
mailpiece 23h
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CA 02591364 2007-06-05
similar in most respects to mailpiece 23a (FIG. 7), includes a pair of spacers
in the form of
rectangular inserts 118a,b. Each of the inserts 118a,b may be a generally
flat, rectangular
member defined by top and bottom edges 124, 126 and lateral edges 120, 122 and
having a
length substantially extending across the opening 43 of mailpiece 23h. Inserts
118a,b may be
made of any suitable material to provide the functionality of the spacers
37c,d (FIG. 6), thereby
limiting bending of article 16 when riding over the surface 13 of a crown
roller 12 (FIGS. 1-3).
Since inserts 118a,b may be in direct contact with the article 16, the
material and construction of
inserts 18 may also be suitable to contact the surfaces of frangible article
16 without damaging
such contacting surfaces.
[00106] Inserts 118a,b are positioned such that they both lie generally facing
each other
but respectively adjacent opposite sides 117, 119 of the article 16. Persons
of ordinary skill in
the art will appreciate that inserts 118a,b may have a different length and/or
height, have a shape
other than rectangular, have different respective thicknesses, be made of two
different materials
or both be placed at a different location with respect to central axis 19 of
article 16. Inserts
118a,b may alternatively be coupled along their respective lateral edges 120,
122 thereby
defining a sleeve of suitable dimensions to retain of article 16. Inserts 11
8a,b may also be
coupled along their respective lateral edges 120, 122 and bottom edges 126 so
as to define a
pocket into which article 16 may be inserted prior to insertion of the article
16 and defined
pocket into the mailpiece 23h.
[00107] Article 16 and inserts 118a,b may be inserted into mailpiece 23h in
the direction
indicated by arrow 130, with a final resting position as indicated by the
phantom-line rectangle
132, thereby defining the configuration of the general embodiment depicted in
FIG. 6. While the
embodiment of FIG. 16 is depicted having two individual inserts 118a,b
separable from
mailpiece 23h, an alternative embodiment may include an insert 118a,b pre-
attached to the inner
surface of either panel 42, 44 and a separable insert 118a,b adapted to be
inserted along with
article 16 such that both inserts 118a,b lie adjacent opposed sides 117, 119
of the article 16 when
article 16 is within mailpiece 23h. Upon application of pressure 28 (FIG. 6)
against the belts 11,
the behavior of mailpiece 23h and article 16 is similar to that of spacers
37c,d (FIG. 6), showing
the general principles of the behavior of mailpieces having spacers with this
type of
configuration.
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CA 02591364 2007-06-05
[00108] With reference to FIG. 17 in which like reference numerals refer to
like features
of FIG. 16 and in accordance with an alternative embodiment of the invention,
a mailpiece 23i
similar to mailpiece 23h (FIG. 16) includes a Z-shape sleeve 134 that is
assembled with the
frangible article 16. Sleeve 134 comprises a main panel 141 and two end panels
140, 142
integrally formed with main panel 141. Sleeve 134 may be folded along fold
lines 144, 146 in a
Z-fold configuration, thereby defining the end panels 140, 142 and main panel
141. The Z-fold
of sleeve 134 is such that end panels 140, 142 lie diametrically opposed and
adjacent to opposed
sides 117, 119 of article 16. For example, end panel 140 may be disposed
adjacent to side 117 of
the article 16 while end panel 142 may be disposed adjacent to side 119 of
article 16.
Alternatively, end panel 140 may confront against side 119 while end panel 142
may confront
side 117 of the article 16.
[00109] Sleeve 134 may be made of any suitable material to provide the
functionality of
the pairs of spacers 37a,b (FIGS. 5A,B), thereby limiting bending of article
16 or when riding
over the surface 13 of crown rollers 12 (FIGS. 1-3). Because sleeve 134 may be
in direct contact
with article 16, the material and construction of sleeve 134 may also be
suitable to contact the
surfaces of article 16 without damaging such surfaces. While sleeve 134 is
depicted in FIG. 17
as shown, persons of ordinary skill in the art will appreciate that,
altematively, sleeve 134 may
have end panels of unequal respective lengths and/or heights or jointly have
respective lengths
and/or heights other than those shown, have a shape other than rectangular,
have different
respective thicknesses, be made of two different materials or both be placed
at different locations
with respect to central axis 19 of article 16.
[00110] Article 16 and sleeve 134 may be inserted into mailpiece 23i in the
direction
indicated by arrow 130, thereby defining the configuration of the general
embodiment depicted
in FIGS. 5A-5B. Upon application of pressure 28 against the belts 11 (FIG. 4),
the behavior of
mailpiece 23i and article 16 is similar to that described in the embodiment of
FIGS. 5A-5B,
showing the general principles of the behavior of mailpieces having spacers
with this type of
configuration.
[00111] With reference to FIG. 18 in which like reference numerals refer to
like features
in FIG. 15 and in accordance with an alternative embodiment of the invention,
sleeve 108 may
be modified to omit spacers 110a,b, 112a,b but, in their place, to include
spacers 80a,b of a
length substantially equal to the length of sleeve 108, and substantially
extending between lateral
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CA 02591364 2007-06-05
edges 86, 88. Spacer 80a comprises a folded section along edge 92 of panel 87
so as to locally
increase the effective thickness of panel 87. Spacer 80b comprises a folded
section along edge
79 of panel 85 so as to locally increase the effective thickness of panel 85.
The spacers 80a,b
may each comprise any type of fold such as a bifold, trifold or z-fold, such
as to create a suitable
effective local thickness increase. Spacers 80a,b may comprise adhesive
members (not shown)
to facilitate retention of the fold along each of the top and bottom edges
79a. Alternatively,
securing members, such as adhesive tape, or coupling components, such as
staples, may be
applied over the folded sections to secure the respective folds of spacers
80a,b. The spacers
80a,b are arranged in compliance with the arrangement of spacers 37c,d (FIG.
6). The spacers
80a,b may extend along substantially the entire length of sleeve 108 or may
have unequal lengths
and/or respective lengths that are shorter than 108 effective to mitigate the
flexing of the article
16.
[00112] With reference to FIGS. 19, 20, and 20A in which like reference
numerals refer to
like features in FIGS. 1-3 and in accordance with an alternative embodiment of
the invention, a
generally square or rectangular mailpiece 150 includes opposed panels 151, 153
defining a
mailpiece opening 155. The mailpiece 150 has top and bottom edges 154, 156 and
lateral edges
152a,b. Mailpiece 150 may further include a flap 157, integrally formed with
panel 153 along a
fold line (not shown), having an adhesive portion 157a suitable to adhere flap
157 to the outer
surface of panel 151 or any other non-adhesive components suitable to couple
the two surfaces
involved. A person having ordinary skill in the art will appreciate that the
flap 157 of mailpiece
150 may have a different shape, size, material, or relative location or the
flap 157 may be omitted
so long as the configuration or mailpiece 150 is such that it protects and
generally encloses the
contents therein.
[00113] Mailpiece 150 fizrther includes a spacer 158 coupled to the inner
surface of one of
the panels 151, 153 or integrally formed therewith. Spacer 158 is adapted to
fit into the center
opening 21 of the article 16 and is vertically positioned within mailpiece 150
such that the spacer
158 will traverse a path above or below circumference 26 of roller 12 (FIG.
2). Spacer 158 has a
thickness or axial dimension, A, that is larger than the thickness of the
article 16.
[00114] As best shown in FIG. 20A, spacer 158 includes a hub portion 160 and a
flange
portion 162 coupled to one end of the hub portion 160. When the spacer 158 is
inserted into
center opening 21, the hub portion 160 projects beyond the plane of one side
117 of the article 16
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CA 02591364 2007-06-05
and the flange portion 162 projects beyond the plane of the opposed side 119.
The flange portion
162 is disposed between side 119 of the article 16 and panel 153. Hub portion
160 may be of
any suitable shape to provide a surface area against which panel 151 may be
abutted. Flange
portion 162 may be of any suitable shape to provide a surface area against
which panel 153 may
be abutted. Once article 16 is placed into mailpiece 150, the effective
thickness of the mailpiece
150 local to the central axis 19 of the article 16 is increased. The diameter
of flange portion 162
is greater than the diameter of the center opening 21 of article 16.
Consequently, belt pressure
28 (FIG. 3) cannot displace the spacer 158 relative to the center opening 21
and hub 19.
[00115] The hub region 160 of the spacer 158 is diametrically smaller than the
center
opening 158. As a result, the article 16 is free to move and freely rotate
relative to the hub
region 160, as opposed to being anchored in the mailpiece 150. The location of
the spacer 158
inside the mailpiece 150 is based on the position of the article 16 relative
to the circumference 26
and opposite rims 30a,b of the roller 12 (FIG. 2) in order to optimize the
mitigation. The shape
of hub portion 160 can be circular, oblong or oval, stared, square, etc.
[00116] With reference to FIG. 20B, a mailpiece 150a with opposed panels 151,
153
includes a spacer 158a. Spacer 158a is illustrated as having a uniform
diameter across its axial
dimension, A, which is perpendicular to the radius. As a result, spacer 158a
differs from spacer
158 (FIGS. 19, 20, 20A) in that the hub and flange portions 160, 162 have a
constant diameter.
When spacer 158a is positioned in the center opening 21, spacer 158a does not
contact either
side 117, 119 of the article 16. Spacer 158a has a smaller diameter than the
diameter of the
center opening 21 of article 16. The length is greater than a thickness
between the sides 117,
119 of the article 16. The invention contemplates that the spacer 158a may be
tapered along its
length so long as the maximum diameter is less than the diameter of the center
opening 21 of
article 16.
[00117] With reference to FIG. 20C, a mailpiece 150b has opposed panels 151,
153 and a
radially compressible and resilient spacer 158b. Spacer 158b may be manually
pre-compressed
by the user prior to engaging it into center opening 21 of the article 16.
Alternatively, the article
16 may be pushed onto spacer 158b, which causes radial compression of spacer
158b to occur
and thereby allows positioning of the spacer 158b inside the center opening
21. Once positioned
in the center opening 21, spacer 158b may expand, thereby comprising a central
hub portion
161b and opposed cylindrical flange portions 160b, 162b. Flange portion 160b
contacts side 117
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CA 02591364 2007-06-05
and flange portion 162b contacts side 119. Alternatively, spacer 158b may be
such that, once
engaged into center opening 21, spacer 158b expands to thereby comprise a
spacer having a non-
cylindrical central portion and/or non-cylindrical flange portions.
[00118] With reference to FIGS. 21 A,B in which like reference numerals refer
to like
features in FIGS. 1-3 and FIGS. 19, 20, 20A and in accordance with an
alternative embodiment
of the invention, mailpiece 150, including spacer 158 and holding article 16,
is shown
transported by belts 11 over the crowned surface 13 of a roller 12 such as the
roller in the
embodiment of FIG. 4 and the description of which maybe referred to for an
understanding of
the roller of FIGS. 21A,B as well. The article 16 and spacer 158 are
positioned inside the
mailpiece 150 to optimize the effectiveness of spacer 158 in view of all
mailpiece design
parameters. For example, a lifting mechanism, such as inserts or a pocket (not
shown), may be
used to position the article 16 inside the mailpiece 150 to optimize the
effectiveness of the spacer
150 by ensuring that the centerline of spacer 158 (which coincides with axis
19) does not
coincide with the circumference 26 of roller 12.
[00119] With reference to FIG. 21A, mailpiece 150 is oriented such that panel
153 sides
the roller 12 while belt pressure is applied in a direction as indicated by
arrows 28a. Spacer 158
is vertically positioned in mailpiece 150 such that the spacer 158 will
traverse a path above
circumference 26 of roller 12. Alternatively and although not shown, spacer
158 may be
vertically positioned in mailpiece 150 such that the spacer 158 will traverse
a path below
circumference 26 of roller 12. Pressure 28a exerted by the belts I 1 onto the
mailpiece 150 and
the article 16 will result in the mailpiece 150 contacting the roller at a
point proximate contact
point 24 of roller 12 and the outer surface of the spacer 158 adjacent to
panel 153 deforming to
conform to the crown surface of the roller 12. Spacer 158 will indirectly
contact (through panel
153) the roller 12 in a region generally above circumference 26. The bending
or flexing of
article 16 is substantially limited due to the abutment of hub 18 of article
16 against the inner
surface of flange portion 160, which remains substantially flat and parallel
to hub 18. The
bending or flexing of article 16 is further limited due to the pressure of the
belts I 1 being exerted
onto the spacer 158, and not onto the article 16, causing the deformation and
relative motion of
spacer 158 with respect to the center opening 21 of article 16.
[00120] With reference to FIG. 21B, mailpiece 150 is oriented such that panel
151 sides
the roller 12 while belt pressure is applied in a direction as indicated by
arrows 28b. Spacer 158
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CA 02591364 2007-06-05
is vertically positioned in mailpiece 150 such that the spacer 158 will
traverse a path above
circumference 26 of roller 12. Alternatively, spacer 158 may be vertically
positioned in
mailpiece 150 such that the spacer 158 will traverse a path below
circumference 26 of roller 12.
Pressure exerted by the belts 11 onto the mailpiece 150 and the article 16
will result in the
mailpiece contacting the roller at a point proximate contact point 24 and in
the outer surface of
the spacer 158 adjacent to panel 151 being deformed to conform to the crown
profile of the roller
12. Spacer 158 will indirectly contact (through panel 151) the roller 12 in a
region generally
above circumference 26. The bending or flexing of article 16 is substantially
limited due to the
pressure of the belts 11 being exerted onto the spacer 158, and not onto the
article 16, causing the
deformation and relative motion of spacer 158 with respect to the center
opening 21 of article 16.
[00121] With reference to FIGS. 22A,B and in accordance with an alternative
embodiment
of the invention, the invention contemplates that one or more spacers may be
placed directly on
the frangible article, as opposed to carried on an insert loosely positioned
inside a mailpiece,
directly coupled with a mailpiece, or carried by a sleeve inserted into the
mailpiece. Specifically,
a frangible article 16a, which is constructed otherwise similarly to article
16, includes a front
side 11 7a, a back side 11 9a, a hub 18a, a center opening 21 a, and a central
axis 19a. Article 16a
further includes annular spacers 170a,b that are concentric with center
opening 21 a and located
on the hub 18a on a respective one of opposed sides 117a, 119a. Annular
spacers 170a,b may be
constructed from a flexible material that permits deformation when pressure
28a from
conventional belts 11 (FIGS. 21A,B) acts thereupon or may be composed of a
rigid material that
does not deform under the influence of pressure 28a. Annular spacers 170a,b
have a diameter
larger than the diameter of the center opening 21 a such that they do not
interfere with the writing
and reading of information respectively to and from a media region 20a of
article 16a.
[00122] The annular spacers 170a,b may be adhesively bonded to the sides 1 l
7a, 119a of
the hub 18a. Alternatively, the annular spacers 170a,b may be integrally
formed with the article
16a during, for example, a molding process.
[00123] Article 16a may be placed in mailpiece 150 with the central axis 19a
positioned
such that the spacer 170a,b traverse a path above or below circumference 26 of
roller 12 (FIGS.
21A,B). The mailpiece 150 may be configured with a pocket, interior sleeve or
the like, to place
the article 16a in this location. Upon exertion of belt pressure 28b (FIGS. 21
A, B), the behavior
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CA 02591364 2007-06-05
of article 16a and the mailpiece 150 will be as described for the general
embodiment of FIGS.
21 A,B, which may be referred to for an understanding of this exemplary
embodiment as well.
[00124] While the present invention has been illustrated by a description of
various
embodiments and while these embodiments have been described in considerable
detail, it is not
the intention of the inventor to restrict or in any way limit the scope of the
appended claims to
such detail. Additional advantages and modifications will readily appear to
those skilled in the
art. Thus, the invention in its broader aspects is therefore not limited to
the specific details,
representative apparatus and method, and illustrative example shown and
described.
Accordingly, departures may be made from such details without departing from
the spirit or
scope of the general inventive concept.
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