Technical Field
[0001] The present subject matter relates to techniques and equipment to print forms that
can be used in a document processing system that individually wraps each form in a
manner that produces a mailpiece that is both an outbound (i.e. going to a customer)
and a return mailpiece (i.e. returned to a business). In addition, the printed form
may optionally contain advertisements, coupons, inserted documents, statements and
payment coupons.
Background
[0002] Current mail production operations have seen many changes and trends over the past
decade, including increases in costs, shrinking margins, lower volumes, market consolidation,
changing postal regulations, and increased competition. What has remained constant,
however, is the need to produce communication pieces that derive a desired response,
and are produced with integrity and in a highly automated and efficient manner.
[0003] The current systems that mailers use for creating the majority of their work range
from low-speed inserters with no intelligence to high-speed finishing systems that
are intelligent and connected to some form of an automated document factory. The systems
used are typically determined by the application being processed and the capital investment
available for growth.
[0004] Existing inserting systems have many factors that determine their overall speed and
efficiency. Even high-end systems have limitations that prevent them from realizing
their maximum potential. These limitations include: the number of supported input
channels; the speed at which materials are personalized and assembled; and the number
of stops from jams or other errors; the rate at which inserts can be added.
[0005] Current document processing approaches involve creating a document, such as a statement,
to be folded and inserted into a pre-manufactured envelope. The envelope is frequently
windowed to allow the address printed on the document to be seen through the window.
This approach is favored for personal mail versus printing the address after the mailpiece
manufacture is completed. The window approach is used to insure that the contents
of the mailpiece and address match. In addition, coupons and inserts are separately
printed and cut and matched with the document prior to insertion into the windowed
envelope. Frequently, a return mail envelope is separately manufactured and inserted
into the envelope with the other material. This process and inserter system are very
complex with multiple feeders and cutters and numerous pieces of material that need
to be manufactured in separate processes and loaded numerous times on to the inserter.
[0006] Hence a need exists for a mail preparation process that uses a prepared group of
forms printed on a paper roll which is processed on a wrapping document processing
system that eliminates the separate steps mentioned above to create a multi-function
mailpiece.
Summary
[0007] It is desirable to provide an article of manufacture for use as an integrated bidirectional
mailpiece having outgoing and return envelope functionality. The article includes
a sheet of paper having printed material on first and second sides of the paper. The
paper includes a first panel having a first address for the outgoing envelope; a second
panel including a second address for the return envelope, with the second address
being different from the first address; a third panel between the first and second
panels. At least one adhesive region is positioned on at least one side of the paper.
At least one fold line extends across a width of the paper between the first and second
panels. At least one perforated line extends across a width of the paper for separating
the first panel from the paper.
[0008] It is further desirable to provide a method of creating an integrated bidirectional
mailpiece having outgoing and return envelope functionality. The method includes printing
information on both sides of a paper. The paper having a first panel including a first
address for the outgoing envelope; a second panel including a second address for the
return envelope, the second address being different from the first address; and a
third panel between the first and second panels. The paper is folded along fold lines
to form the mailpiece such that the address on the first panel is viewable on an exterior
of the mailpiece, and the address on the second panel is concealed in an interior
of the mailpiece. The folded paper is sealed along one or more adhesive portions positioned
along one or more surfaces of the mailpiece.
[0009] It is yet further desirable to provide a method for producing a bidirectional integrated
mailpiece having outgoing and return envelope functionality. The method includes receiving
a continuous web of pre-printed paper from a paper stock. The pre-printed paper contains
a first address for the outgoing envelope in a first panel and a second address for
a return envelope in a second panel. At least one adhesive region is applied to a
surface of at least one side of the sheet of paper. At least one fold line is created
and extends across a width of the sheet of paper between the first and second panels.
A perforated line is generated and extends across a width of the paper such that the
first panel can be separated from the paper. The paper is folded along a plurality
of fold lines such that the first address on the first panel is viewable on an exterior
of the mailpiece. The second address on the second panel is concealed in an interior
of the mailpiece. The folded paper is sealed along one or more adhesive portions to
form the mailpiece.
[0010] In yet another example, a method for producing an article of manufacture for use
as an integrated bidirectional mailpiece having outgoing and return envelope functionality
is provided. The method includes receiving paper from a paper stock. A first address
is printed on a first panel for the outgoing envelope. A second address is printed
on a second panel for the return envelope, with the second address being different
from the first address. One or more adhesive regions is applied to a surface of at
least one side of the paper. At least one fold line is created and extends across
a width of the sheet of paper between the first and second panels. A perforated line
is generated and extends across a width of the paper such that the first panel can
be separated from the paper.
[0011] It is further desirable to provide a system for generating a bidirectional integrated
mailpiece having outgoing and return envelope functionality. The system includes a
printer configured to print information on at least one side of a sheet of paper.
The sheet of paper includes a first address on a first panel for the outgoing envelope
and a second address on a second panel for the return envelope, with the second address
being different from the first address. A glue applicator is configured to apply one
or more adhesive regions on at least one side of the sheet of paper. A perforator
is configured to create a perforated line extending across a width of the paper between
the first and second panels. A folder is configured to fold the sheet of paper along
one or more fold lines such that the first address on the first panel is viewable
on an exterior of the mailpiece, and the second address on the second panel is concealed
in an interior of the mailpiece.
[0012] Further, it is desirable to provide for an article of manufacture for use as an integrated
bidirectional mailpiece having outgoing and return envelope functionality to be initially
assembled by way of a wrapper. The article includes a duplex printed paper having
printed material on first and second sides of the paper. The paper includes a first
panel including a first address for the outgoing envelope; a second panel including
a second address for the return envelope, the second address being different from
the first address; and a third panel including one or more of the following: a statement,
a return payment stub, coupon, or advertisement. At least one adhesive region is positioned
on at least one side of the paper. At least one fold line extends across a width of
the paper between the first and second panels. A plurality of perforated lines extends
across a surface of the paper for separating the first and third panels from the paper,
such that when the first and third panels are separated, the second and third panels
are sufficient to form the return envelope.
[0013] It is further desirable to provide a method for producing a bidirectional integrated
mailpiece, on a wrapping document processing system, having outgoing and return envelope
functionality. The method includes duplex printing on paper, a first address on a
first panel for the outgoing envelope and printing a second address on a second panel
for the return envelope, wherein the second address being different from the first
address. One or more of the following is printed on one or more portions of a third
panel: a statement, return payment stub, coupon or advertisement. At least one adhesive
region is applied to a surface of at least one side of the paper. A plurality of perforated
lines is generated across a surface of the paper such that the first and third panels
can be separated from the paper, such that when the first and third panels are separated,
the second and third panels are sufficient to form the return envelope.
[0014] It is yet further desirable to provide a method of manufacturing an integrated bidirectional
mailpiece having outgoing and return envelope functionality. The method includes duplex
printing information on paper. The paper includes a first panel including a first
address for the outgoing envelope, a second panel including a second address for the
return envelope, the second address being different from the first address, and a
third panel including one or more of the following: a statement, a return payment
stub, coupon, or advertisement. The paper is folded along fold lines such that the
address on the first panel is viewable on an exterior of the mailpiece. The address
on the second panel and the statement on the third panel are concealed in an interior
of the mailpiece. The folded paper is sealed along one or more adhesive portions positioned
along one or more surfaces to form the mailpiece.
[0015] Additional objects, advantages and novel features will be set forth in part in the
description which follows, and in part will become apparent to those skilled in the
art upon examination of the following and the accompanying drawings or may be learned
by production or operation of the examples. The objects and advantages of the present
teachings may be realized and attained by practice or use of the methodologies, instrumentalities
and combinations particularly pointed out in the appended claims.
Brief Description of the Drawings
[0016] The drawing figures depict one or more implementations in accord with the present
teachings, by way of example only, not by way of limitation. In the figures, like
reference numerals refer to the same or similar elements.
[0017] FIG. 1 is a diagram of a wrapping document processing system that can create a multi-function
mailpiece from single page forms printed on a paper roll.
[0018] FIG. 1A is a representation of a wrapping document processing system with emphasis
on the wrapping mailpiece preparation subsystem.
[0019] FIGS. 2A and 2B are an exemplary single page forms for the inside and outside of
a mailpiece, respectively.
[0020] FIG. 3 is a diagrammatic representative of the components of the system needed to
create the multi function mailpiece.
[0021] FIG. 3A is a representative drawing of a hot glue application system.
[0022] FIG. 3B is a representative drawing of a wrapping system.
[0023] FIGS. 4A and 4B are exemplary single page forms for the inside and outside of a mailpiece,
respectively.
[0024] FIG. 5 is an exemplary return mailpiece showing the markings required for business
reply mail.
[0025] FIG. 6 is an exemplary process flow of the paper roll creation and wrapping document
processing system operational steps.
[0026] FIG. 7 illustrates a network or host computer platform, as may typically be used
to implement a server.
[0027] FIG. 8 depicts a computer with user interface elements, as may be used to implement
a personal computer or other type of work station or terminal device.
Detailed Description
[0028] The present teachings alleviate one or more of the above noted problems by providing
a process to provide an integrated mailpiece using a document processing system such
as a wrapping document processing system. The manufactured mailpiece is an integrated
bidirectional mailpiece having outgoing and return envelope functionality. In the
outgoing format, the integrated mailpiece may optionally contain advertisements, coupons,
inserted documents, statements or payment coupons. Other documents may be added to
the mailpiece as inserts.
[0029] A plurality of forms containing the group of items listed above are aggregated and
printed on a paper roll. Some types of glue strips and perforation tear or fold lines
maybe added to the roll of paper before it enters the printer or immediately after
printing. The finished printed roll of paper is processed on a wrapping document processing
system that will add glue strips and perforations as needed and wrap the prepared
paper along fold lines to form an integrated bidirectional mailpiece with outbound
and return mailpieces. The resulting strip of paper is cut to form the individual
outbound mailpieces. The outbound mailpiece may optionally contain other documents
which may be added as inserts.
[0030] The present teachings provide an eco-friendly document processing system that dynamically
is capable of creating personalized bills and statements at significant savings over
conventional mailpieces. The present system enables the creation of documents in all
standard formats on a single machine, delivers significant improvements in efficiency,
and dramatically reduces paper costs and usage.
[0031] In certain examples, the present teachings provide for document processing system
uses roll-fed material to create an integrated bidirectional mailpiece that replaces
the traditional elements in a statement or invoice: the outgoing envelope, statement,
optional promotional inserts, remittance and return envelope. Thus, conventional outgoing
and return envelopes are eliminated through the present document processing system
and waste associated with shipping, storing, handling, and printing of these conventional
materials is also avoided.
[0032] In the following detailed description, numerous specific details are set forth by
way of examples in order to provide a thorough understanding of the relevant teachings.
However, it should be apparent to those skilled in the art that the present teachings
may be practiced without such details. In other instances, well known methods, procedures,
components, and circuitry have been described at a relatively high-level, without
detail, in order to avoid unnecessarily obscuring aspects of the present teachings.
[0033] Reference now is made in detail to the examples illustrated in the accompanying drawings
and discussed below. FIG. 1 illustrates a wrapping document processing system 100.
As illustrated, there are two major subsystems 101 and 102. The first subsystem is
the wrapping mailpiece preparation subsystem 101, which forms a bidirectional mailpiece
170 from a single page form (FIGS. 2A, 2B; 4A, 4B or 5), that originate on a paper
roll 140. The Bowe Bell + Howell MAILStream Inveloper is an example of a machine that
contains the technology needed to configure the wrapping mailpiece preparation subsystem
101 plus the insert feeders 136 and 135 of the document and insert subsystem 102.
A bidirectional mailpiece is characterized by the formation of both an outbound mailpiece
and a return mailpiece which is created from numerous single page forms printed on
a continuous roll of paper. The bidirectional mailpiece is not cut from the continuous
web of paper 141 containing a stream of printed forms 95 or 95a until the mailpiece
170 is completed. The document and insert subsystem 102 is the second subsystem. This
subsystem is optional to the formation of a bidirectional mailpiece 170 however; this
subsystem 102 can be readily integrated onto the wrapping mailpiece preparation subsystem
101. The subsystems 101 and 102 may or may not be under the control of one or more
control processors 200, which coordinates and controls the actions of one or more
devices within the subsystems 101 and 102.
[0034] The wrapping mailpiece preparation subsystem, referred as subsystem 101 hereafter,
is designed to take pre-print forms 95 or 95a on a paper roll 140 and prepare the
roll of paper 140 to be formed into a bidirectional mailpiece. Details of the form
are discussed in FIGS. 2A and 2B. The continuous web of paper 141, from the paper
roll 140, is fed under the perforation and glue section 150 to an optional printer
145. Additional data can be printed on the forms as the web passes through the printer
145. For example, if the forms 95 or 95a did not contain any customer specific data
then the customer's address maybe printed by the printer 145. Mailpiece designers
skilled in the art can add any required additional printed data as desired with the
printer 145 option. The continuous web 141 proceeds to the perforation and glue section
150 where various glue types are applied and longitudinal perforations are added as
required. FIG. 3 provides additional detail for the operation of the perforation and
glue section 150. The continuous web 141 is reoriented in direction by 90 degrees
in the perforation and glue section 150 and fed into the wrapping section 103 where
individual panels 92, 94 are wrapped along the fold lines 40 and 45, as shown in FIGS.
2A and 2B.
[0035] Following the wrapping step 103, which also seals any pressure sensitive or contact
glue strips, the completed out bound mailpiece 165, which is still a part of the continuous
web 141, goes into a set of perforation rollers 155 and then into a set of cutter
rollers 160 for cutting the out bound mailpiece 165 from the wrapped (folded) continuous
web 141a to form the finished mailpiece 170. The finished mailpieces 170 will be transferred
to the output section 175 where the finished mailpieces will be stacked and grouped
into mail trays, either automatically or with operator assistance. The perforation
rollers 155 can be designed in numerous styles based on the positioning of the perforation
cutters. These variations make it possible to cut all layers of the outbound mailpiece
170, cut only selected layers and to limit the perforation cuts to only a partial
section instead of the full width.
[0036] The document and insert subsystem 102 is required if inserts are desired to be part
of the outbound mailpiece 170. Documents are either on a roll of paper 105 or in a
fan folded stack of paper. The documents are fed into a cutter 110 to make individual
sheets and then into an accumulator folder 115 to accumulate multiple sheets that
make up the document and then fold the sheets into a form facter compatable with the
space available in the wrapped return mailpiece. The Bowe Bell + Howell 310 High Speed
Cutter and the 4911 Combined Accumulator/folder are representative to the technology
required for items 110 and 115 respectively. The assembled document 120 is placed
on a collation track 125. The collation track 125 will advance the document 121 under
an insert feeder 135 where an insert will be added to form a collection material including
inserts and a document 122. If additional inserts are required, additional feeders
136 are used to add inserts 123 to the collection of material to be wrapped into the
out bound mailpiece 165.
[0037] The collation track 125 is either moving the documents at the same speed as the paper
web 141 or synchronizes the speed of the last group of inserts and document 123 so
that the inserts and document can be placed onto the correct area of the center panel
93 or 98 (optional insert positions 96, 96a and 96b in FIGS. 2A, 4A and 5, respectively).
The components and features of both the wrapping mailpiece preparation subsystem 101
and the document and insert subsystem 102 can be reconfigured, by those skilled in
the art, to support numerous bidirectional mailpiece designs that are suitable for
operation on a wrapping document processing system 100.
[0038] In FIG. 1A, a representation of a wrapping document processing system with emphasis
on the wrapping mailpiece preparation subsystem 101 is shown. The majority of FIG.
1A is devoted to the wrapping mailpiece preparation subsystem 101 with only the trailing
edge of the collation track 125 shown for the document and insert subsystem 102. The
paper roll 140 is shown installed on the support and unwind mechanism 104 with the
paper web 141 entering the perforation and glue system 150. The optional printer is
not shown as well as the sub-components of the peroration and glue system 150. A portion
of the wrapping section 103 is visible next the perforation rollers 155 and the cutting
rollers 160. The output section is not shown but it attached at location 175.
[0039] Referring to FIGS. 2A and 2B for an exemplary illustration of form 95 that demonstrates
many of the features that maybe included in the bidirectional mailpiece. FIG. 2A shows
the face up side of the form 80 as it comes off the paper roll 140 and as it transitions
into the wrapping section 103. The direction of travel through the machine is indicated
by arrow 5. FIG. 2B is the face down side of the form 90 as it comes off the paper
roll 140 and as it transitions into the wrapping section 103. To correctly visualize
the face down or backside of the form 90 as it is duplex printed, rotate form 90 counterclockwise
under the upward facing form 80. As a result, the printed material 86 is directly
underneath the optional insert 96 section of form 80. The form 80 is divided into
three panels 92, 93 and 94 which will be folded in the wrapping section 103. Each
panel can contain a variety of options for the printed material. The examples in FIGS.
2A and 2B are not intended to be limiting in nature and are provided as possible examples.
The sample form 95 is an example of an electric bill with a statement 84 and a payment
coupon 81 that are primarily on panel 92, but overlap across the fold line 40 into
panel 93. Perforation 35 is produced either during the preparation of the printer
ready roll of paper 332 (FIG. 3) or is added by a perforation wheel in the perforation
and glue section 150. Perforation 35 is needed to enable the customer to remove the
statement from what will become the return envelope in the wrapping section 103. The
bottom side of panel 92 is the customer address 87.
[0040] The return mailpiece is created with panels 93 and 94. Printed information is provided
to the customer in the form of additional company information 82 and a coupon 83.
Those skilled in the art, may provided printed material on the inside of the return
envelope at location 94a that will be used when the return envelope is processed at
the receiving location. The bottom side of panel 93 contains instructions 86 on opening
the mailpiece and making a payment with the payment coupon and a method of payment
such as a check. Additional information 88 can be printed in the back side of panel
93. The printed information in sections 81, 82, 84, 84, 86 and 88 can be used for
numerous purposes, such as, but not limited to statements, advertisements, coupons,
customer alerts and instructions, depending on the type of mailpiece being generated.
The return address 85 is printed on the bottom side of panel 94. Glue strips are applied
in the perforation and glue section 150. If pressure glue is used, either glue strips
30 and 32 or 20 and 22 are applied. Both strips are not needed for pressure sensitive
glue. Other glue options are possible such as contact glue which will only bind when
the opposite glue strip comes in contact. In this case, all four strips maybe applied.
If optional inserts 96 are required they are placed on the panel 93 before the wrapping
section 103 (FIG. 1). With either glue option, the return mailpiece will be formed
by the wrapping section 103 where panel 94 will be folded onto panel 93 and the glue
pressure sealed. The glue is applied with a jet system or a roller with a glue applicator.
Those skilled in the art will adapt existing application technology based on the application
requirements. A moistenable glues strip 10 is applied to the paper roll 330 (FIG.
3) where sufficient drying time is allotted or the moistenable glues strip 10 can
be applied in the perforation and glue section 150. If the glue is applied in section
150, a heat source or forced air maybe added to ensure that the glue is dry before
the paper web 141 reaches the wrapping section 103. The moistenable glue is part of
the return mailpiece flap that is made by applying a fine perforation or by adding
a crease with opposing rollers to form the flap fold line 55. The outbound mailpiece
170 is formed by first wrapping panel 94 on top of panel 93 to form the return mailpiece
and then wrapping panel 92 along fold line 40. A fugitive glue strip 60 is applied
to panel 92 in the perforation section 150 to seal panel 92 to the folded bottom side
of panel 94. As a reference, the fugitive glue will adhere to panel 94 below the barcode
85a. This is the final step in the wrapping section 103. Fugitive glue is an easily
removed glue with low adhesion, similar to the glue on a Post-it
® note. However, fugitive glue as used in this application is not intended to re-adherable.
Glue spots maybe used in place of a glue strip 60. Following the wrapping section
103, perforation rollers are used to form the perforation line 50 by cutting perforations
through the closed mailpiece. The out bound mailpiece 170 is cut from the continuous
web 141a with cutter rollers 160.
[0041] FIG. 3 identifies an exemplary illustration of the component parts needed to form
a bidirectional mailpiece 170. The processes as identified maybe performed by separately
run processes done at different times or even by different companies. The process
starts with a blank paper roll 330. Perforations 35 and moistenable glue strips 10
maybe applied to the blank roll of paper 330 with a perforation wheel system 340 and
glue applicator 335 respectively. Depending on the production setup, the paper web
from roll 330 maybe re-rolled 332 after the glue has dried or sent directly into the
printer 333. The printer 333 maybe duplex and color as required for forms 95 and 95a
FIGS. 2A, 2B and 4A, 4B respectively or single sided black and white as illustrated
for form 90b FIG. 5. The printer output is rerolled 140 for use by the wrapping document
processing system 100 or fed directly into the system 100. The optional printing system
145 is not shown.
[0042] The subcomponents of the perforation and glue system 150 have numerous component
types and features that are available and configurable by those skilled in the art
to perform the functions dictated by the form to be processed. The functions of system
150 illustrated in FIG. 3 are in reference to form 95 FIGS. 2A, 2B. A fugitive glue
applicator 350 applies the glue strip 60 to the statement portion. Spraying, wiping,
and rolling glue onto the paper web are common methods but the application process
is not limited to these methods. Optional glue lines 30 and 32 are applied with spraying
system 345. These glue lines are often omitted since they may interfere with the inclusion
of the optional inserts 96 by the document and insert subsystem 102. A glue applicator
340 applies the pressure sensitive glue strips 21 and 22. The fold line 55 for the
return mailpiece flap is created by a very fine perforator or crease rollers 342.
Either method will make it easy for the customer to fold the flap along the fold line
55. The wrapping section 103 will accept the inserts 96 and fold panel 94 along fold
line 45 onto panel 93 and seal the pressure sensitive glue strips 21 and 22. The next
stage wraps panel 92 on top of panel 94 and seals the fugitive glue. Crosswise perforations
50 are created by the perforation rollers 155 and then the outbound mailpiece is cut
from the continuous web 141a with cutter rollers 160.
[0043] FIG. 3A is a representative glue application system 340 and 345 as shown in FIG.
3. The figures depicts an example of a melter 1 such as a ProBlue
® melter make by Nordson Corporation. The melter 1 liquefies solid form hot melt and
maintains the hot melt at the desired temperature. When the glue jets 2 are activated,
the melter pumps the liquefied hot melt through the hoses 3 and out the jet nozzles,
where it is applied to forms 80 and 80a. The melt and pump solid form hot melt materials
are engineered to be liquefied and extruded at temperatures below 230 degrees Celsius.
The glue system is included in the perforation and glue system 150. Other systems,
which are commercially available, are used to apply the fugitive glue 60 and the moistenable
glue 10.
[0044] FIG. 3B is a representative drawing of a wrapping system 103 which has an input of
the continuous paper web 141 and outputs a continuous paper web 141a that has been
folded and sealed and is ready to be cut into individual mailpieces 170 FIG. 1. The
continuous paper web 141 enters the wrapping system 103 from below the deck plate
245 after glue and longitudinal perforations have been applied. The fold line 45,
which is between panels 94 and 95, is formed by the creasing and twisting action created
between roller 210 and guide member 205. Similarly, fold line 40, which is between
panels 92 and 93, is formed by the creasing and twisting action created between roller
225 and guide member 220. Inserts 96, 96a and 96b (not shown) are inserted onto panel
93 by belt 230 and pulley 235 systems. A bottom belt (not shown) is used below belt
230 to ensure that the inserts are moving at the same speed as the continuous paper
web 141. Guide fingers 240 are used to ensure that the inserts are placed flat and
oriented correctly as they are placed on the continuous paper web 141. The continuously
moving paper web and inserts that transition into a wrapping system enables higher
throughput, mailpieces manufactured per hour, than can be achieved by conventional
envelope inserters.
[0045] Turning now to FIGS. 4A and 4B for a second example of a bidirectional mailpiece
which contains a product advertisement 70 with a payment coupon 72. Additional printed
materials 82 and 83 (FIG. 2) are omitted to allow for a smaller return mailpiece while
maintaining a sufficient area for inserts 96a. The return envelope is created by wrapping
panel 97 onto panel 98 and sealing glue lines 20a, 22a. 30a and 32a. Those skilled
in the art may provide printed material on the inside of the return envelope at location
97a that will be used when the return envelope is processed at the receiving location.
The return address 85 is printed on the back of panel 97. The customer address 87
is printed on the back of panel 99 and the mailpiece instructions 86 are printed on
the back of panel 98. The moistenable glue line 10a and the fugitive glue line 60a
are swapped between top and bottom of the form 80a versus the orientation shown for
80 (FIG. 2A). The glue lines 20a, 22a, 30a and 32a are applied in a similar manner
to that already described above. Perforation 35a is made on the blank paper or in
the perforation and glue system 150. The return mailpiece flap is creased or perforated
55a with a perforation wheel or crease rollers. The wrapping sequence is reversed
starting with panel 97 being wrapped onto panel 98 along fold line 40a and sealing
the glue lines 20a, 22a, 30a and 32a. The bidirectional mailpiece is completed by
wrapping panel 99 along fold line 45a and sealing the panel with the fugitive glue
line 60a. The perforation line 75 is created by the perforation rollers 155. However
the perforation cutting blades are shortened to only perforate a single layer and
cut from the bottom. The processes of FIG. 3 can be adjusted to accommodate the FIG.
4 form 95a configuration by those skilled in the art without significant modification
to the wrapping document processing system 100. As shown in FIG. 5 form 90b, business
reply address features 501, 502 and 503 can easily be added to the return address
510 panel. Feature 501 is a machine readable indicator that this is a business reply
mailpiece. Feature 502 is an indication of business reply postage requirements and
feature 503 is a human readable indication that the mailpiece is a business reply
mailpiece along with an indication of the class of delivery service requested and
a permit number for postage billing. This exemplary form 90b is processed in a similar
manner as the previously described forms with glue strips, perforations, fold lines
and flap creases applied by the wrapping system 100 as required.
[0046] FIG. 6 is a process flow of the paper roll 140 creation and the wrapping document
processing system 100 operational steps. This process will produce a bidirectional
mailpiece from a single sheet of paper which is cut from a continuous web 141 of paper
after the mailpiece is created. Steps S405 through S415 involve the creation of the
printed material to be processed on the wrapping document processing system 100. The
process starts with a blank paper roll of paper 330. In step S405 a moistenable glue
strip 10 is applied and lengthwise perforations 35 are created. These functions also
can be performed in the perforation and glue system 150. Step S410 defines the duplex
printing of the top side of the paper, forms 80 or 80a and the bottom side of the
paper with forms 90 or 90a which are printed on the roll of paper 332. The roll of
paper 332 may have a longitudinal glue strip and perforation, as required by the applications
being run on the wrapping document processing system 100. The bottom side forms 90,
90a or 90b will have at least the customer address and the return address. Form 90b
(FIG.5) is only printed on the bottom side hence duplex printing is not required.
Step S415 defines the optional printed material that may be added to the printed roll.
The top side 80 or 80a printed material may include but is not limited to coupons
83, 82; statement or advertisements 70, 84; or return coupons 72, 81. For the bottom
side 90, 90a or 90b, printing may include but is not limited to the return address
85 plus other items needed for a valid return mailpiece; instructions for opening
and using the return mailpiece 86; a customer address 87; and other printed items
needed to make a valid outbound mailpiece.
[0047] Steps S420 through S455 are performed by the wrapping document processing system
100. The paper roll 140 is loaded onto the wrapping machine 100 in step S420. The
paper roll 140 contains the duplex printed forms 95 and 95a or the single sided form
90b plus perforations and glue strips as required by the application. The pressure
sensitive glue strips 20, 22, 20a and 22a are applied in step S425. If contact glue
is used, glue strips 30, 32, 30a, and 32a are applied. If optional printing is used,
that step is performed between steps S420 and S425. In step S430, the fugitive glue
60 or 60a is applied. In step S435, either a perforation or a crease line 55, 55a
is applied to make folding of the flap of the return mailpiece easier for the customer
to manipulate. The wrapping and folding process is performed on the continuous web
141 of paper forms in step S445. For form 95 (FIG. 2), the first panel 94 is folded
along fold line 45 and optional inserts and documents 96 are added before the seal
pressure sensitive glue strips 20, 22 are sealed with panel 93. For form 95a, the
first panel 97 is folded along fold line 40a and optional inserts and documents 96a
are added before the seal pressure sensitive glue strips 20a, 22a are sealed with
panel 98. This process forms the return mailpiece. Step S450 completes the outbound
mailpiece 165 for form 95 by folding panel 92 along fold line 40 and then sealing
the fugitive glue 60. For form 95a, panel 99 is folded along fold line 45a and then
sealed with the fugitive glue 60a.
[0048] Step S455 completes the individual outbound mailpiece 170 by forming the perforation
50 across finished mail piece with perforation rollers 155. Alternately the partial
perforation 75 is applied if required. The mailpiece 170 is cut from continuous paper
web 141 with cutter rollers 160. The order of and processes contained in individual
steps can be changed by those skilled in the art to accommodate different form structures
and wrapping document processing system configurations.
[0049] As shown by the above discussion, functions relating to the preparation of the integrated
bi-directional mailpiece may be implemented on one or more computers operating as
the control processor 200 connected for data communication with the processing resources
as shown in FIG. 1. Although special purpose devices may be used, such devices also
may be implemented using one or more hardware platforms intended to represent a general
class of data processing device commonly used to run "server" programming so as to
implement the functions discussed above, albeit with an appropriate network connection
for data communication.
[0050] As known in the data processing and communications arts, a general-purpose computer
typically comprises a central processor or other processing device, an internal communication
bus, various types of memory or storage media (RAM, ROM, EEPROM, cache memory, disk
drives etc.) for code and data storage, and one or more network interface cards or
ports for communication purposes. The software functionalities involve programming,
including executable code as well as associated stored data, e.g. files used for the
work-flow templates for a number of production jobs as well as the various files for
tracking data accumulated during one or more productions runs. The software code is
executable by the general-purpose computer that functions as the control processor
200 and/or the associated terminal device. In operation, the code is stored within
the general-purpose computer platform. At other times, however, the software may be
stored at other locations and/or transported for loading into the appropriate general-purpose
computer system. Execution of such code by a processor of the computer platform enables
the platform to implement the methodology for generating an integrated bidirectional
mailpiece, in essentially the manner performed in the implementations discussed and
illustrated herein.
[0051] FIGS. 7 and 8 provide functional block diagram illustrations of general purpose computer
hardware platforms. FIG. 7 illustrates a network or host computer platform, as may
typically be used to implement a server. FIG. 8 depicts a computer with user interface
elements, as may be used to implement a personal computer or other type of work station
or terminal device, although the computer of FIG. 8 may also act as a server if appropriately
programmed. It is believed that those skilled in the art are familiar with the structure,
programming and general operation of such computer equipment and, as a result, the
drawings should be self-explanatory.
[0052] For example, control processor 200 may be a PC based implementation of a central
control processing system like that of FIG. 8, or may be implemented on a platform
configured as a central or host computer or server like that of FIG. 7. Such a system
typically contains a central processing unit (CPU), memories and an interconnect bus.
The CPU may contain a single microprocessor (e.g. a Pentium microprocessor), or it
may contain a plurality of microprocessors for configuring the CPU as a multi-processor
system. The memories include a main memory, such as a dynamic random access memory
(DRAM) and cache, as well as a read only memory, such as a PROM, an EPROM, a FLASH-EPROM
or the like. The system memories also include one or more mass storage devices such
as various disk drives, tape drives, etc.
[0053] In operation, the main memory stores at least portions of instructions for execution
by the CPU and data for processing in accord with the executed instructions, for example,
as uploaded from mass storage. The mass storage may include one or more magnetic disk
or tape drives or optical disk drives, for storing data and instructions for use by
CPU. For example, at least one mass storage system in the form of a disk drive or
tape drive, stores the operating system and various application software as well as
data. The mass storage within the computer system may also include one or more drives
for various portable media, such as a floppy disk, a compact disc read only memory
(CD-ROM), or an integrated circuit non-volatile memory adapter (i.e. PC-MCIA adapter)
to input and output data and code to and from the computer system.
[0054] The system also includes one or more input/output interfaces for communications,
shown by way of example as an interface for data communications with one or more other
processing systems. Although not shown, one or more such interfaces may enable communications
via a network, e.g., to enable sending and receiving instructions electronically.
The physical communication links may be optical, wired, or wireless.
[0055] The computer system may further include appropriate input/output ports for interconnection
with a display and a keyboard serving as the respective user interface for the processor/controller.
For example, a printer control computer may include a graphics subsystem to drive
the output display. The output display, for example, may include a cathode ray tube
(CRT) display, or a liquid crystal display (LCD) or other type of display device.
The input control devices for such an implementation of the system would include the
keyboard for inputting alphanumeric and other key information. The input control devices
for the system may further include a cursor control device (not shown), such as a
mouse, a touchpad, a trackball, stylus, or cursor direction keys. The links of the
peripherals to the system may be wired connections or use wireless communications.
[0056] The computer system runs a variety of applications programs and stores data, enabling
one or more interactions via the user interface provided, and/or over a network to
implement the desired processing, in this case, including those for generating an
integrated bidirectional mailpiece, as discussed above.
[0057] The components contained in the computer system are those typically found in general
purpose computer systems. Although summarized in the discussion above mainly as a
PC type implementation, those skilled in the art will recognize that the class of
applicable computer systems also encompasses systems used as host computers, servers,
workstations, network terminals, and the like. In fact, these components are intended
to represent a broad category of such computer components that are well known in the
art. The present examples are not limited to any one network or computing infrastructure
model—i.e., peer-to-peer, client server, distributed, etc.
[0058] Hence aspects of the techniques discussed herein encompass hardware and programmed
equipment for controlling the relevant document processing as well as software programming,
for controlling the relevant functions. A software or program product, which may be
referred to as a "program article of manufacture" may take the form of code or executable
instructions for causing a computer or other programmable equipment to perform the
relevant data processing steps regarding the manufacturing of an integrated bidirectional
mailpiece, where the code or instructions are carried by or otherwise embodied in
a medium readable by a computer or other machine. Instructions or code for implementing
such operations may be in the form of computer instruction in any form (e.g., source
code, object code, interpreted code, etc.) stored in or carried by any readable medium.
[0059] Such a program article or product therefore takes the form of executable code and/or
associated data that is carried on or embodied in a type of machine readable medium.
"Storage" type media include any or all of the memory of the computers, processors
or the like, or associated modules thereof, such as various semiconductor memories,
tape drives, disk drives and the like, which may provide storage at any time for the
software programming. All or portions of the software may at times be communicated
through the Internet or various other telecommunication networks. Such communications,
for example, may enable loading of the relevant software from one computer or processor
into another, for example, from a management server or host computer into the image
processor and comparator. Thus, another type of media that may bear the software elements
includes optical, electrical and electromagnetic waves, such as used across physical
interfaces between local devices, through wired and optical landline networks and
over various air-links. The physical elements that carry such waves, such as wired
or wireless links, optical links or the like, also may be considered as media bearing
the software. As used herein, unless restricted to tangible "storage" media, terms
such as computer or machine "readable medium" refer to any medium that participates
in providing instructions to a processor for execution.
[0060] Hence, a machine readable medium may take many forms, including but not limited to,
a tangible storage medium, a carrier wave medium or physical transmission medium.
Non-volatile storage media include, for example, optical or magnetic disks, such as
any of the storage devices in any computer(s) or the like. Volatile storage media
include dynamic memory, such as main memory of such a computer platform. Tangible
transmission media include coaxial cables; copper wire and fiber optics, including
the wires that comprise a bus within a computer system. Carrier-wave transmission
media can take the form of electric or electromagnetic signals, or acoustic or light
waves such as those generated during radio frequency (RF) and infrared (IR) data communications.
Common forms of computer-readable media therefore include for example: a floppy disk,
a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD
or DVD-ROM, any other optical medium, punch cards paper tape, any other physical storage
medium with patterns of holes, a RAM, a PROM and EPROM, a FLASH-EPROM, any other memory
chip or cartridge, a carrier wave transporting data or instructions, cables or links
transporting such a carrier wave, or any other medium from which a computer can read
programming code and/or data. Many of these forms of computer readable media may be
involved in carrying one or more sequences of one or more instructions to a processor
for execution.
[0061] While the foregoing has described what are considered to be the best mode and/or
other examples, it is understood that various modifications may be made therein and
that the subject matter disclosed herein may be implemented in various forms and examples,
and that the teachings may be applied in numerous applications, only some of which
have been described herein. It is intended by the following claims to claim any and
all applications, modifications and variations that fall within the true scope of
the present teachings.
1. An article of manufacture for use as an integrated bidirectional mailpiece having
outgoing and return envelope functionality, the article comprising:
a sheet of paper (95;95a) including printed material on first and second sides of
the sheet of paper (95;95a), the sheet of paper (95;95a) comprising:
a first panel (92;99) including a first address (87) for the outgoing envelope,
a second panel (94;97) including a second address (85) for the return envelope, the
second address (85) being different from the first address (87),
a third panel (93;98) between the first and second panels (92,94;99,97),
at least one first adhesive region (10;10a) positioned on at least one side of the
sheet of paper (95;95a),
at least one fold line (40,45;40a;45a) extending across a width of the sheet of paper
(95;95a) between the first and second panels (92,94;99,97), and
at least one perforated line (35,50;35a,75) extending across a width of the paper
(95;95a) for separating the first panel (92;99) from the sheet of paper (95;95a).
2. The article of claim 1, wherein the at least one first adhesive region (10;10a) comprises
a moistenable glue strip extending substantially across a width of the sheet of paper
(95;95a) along a bottom edge of the sheet of paper (95;95a).
3. The article of claim 1 or 2, further comprising a plurality of second adhesive regions
(20,22,30,32; 20a,22a,30a,32a) selected from the group consisting of: a moistenable
glue strip, fugitive glue strip, and pressure sensitive glue strip.
4. The article of one of claims 1 to 3, wherein the third panel (93;98) includes instructions
for opening the outgoing envelope and assembling the return envelope.
5. The article of one of claims 1 to 4, further comprising a coupon or an advertisement
(72;81-83) printed on the sheet of paper (95;95a).
6. The article of one of claims 1 to 5, wherein at least one third adhesive region (60;60a)
is provided for the outgoing envelope and the at least one first adhesive region (10;10a)
is provided for the return envelope.
7. The article of one of claims 1 to 6, further comprising:
one or more printed elements (71;81-83) comprising one of the following: a statement,
a return payment stub, a coupon, or an advertisement, and
a plurality of perforated lines (35,50;35a,75) extending across a surface of the paper
(95;95a) for separating the first panel (92;99) and the printed elements (71;81-83)
from the paper (95;95a), such that when the first panel (92;99) and the printed elements
(71;81-83) are separated, the second and third panels (92,93 ;97,98) are sufficient
to form the return envelope.
8. The method of claim 7, wherein the one or more printed elements (71;81-83) are printed
on the third panel (93).
9. The article of claim 7 or 8, wherein the statement and the return payment stub are
associated with an addressee identified in the first address (87) on the first panel
(92;99).
10. A method for producing an article of manufacture of one of claims 1 to 9 for use as
an integrated bidirectional mailpiece having outgoing and return envelope functionality,
the method comprising steps of:
receiving paper (330) from a paper stock;
printing the first address (87) on the first panel (92;99) for the outgoing envelope
and printing the second address (85) on the second panel (94;97) for the return envelope;
applying one or more of the first, second or third adhesive regions (10,20,22,30,32,60;10a,20a,22a,30a,32a,60a)
to a surface of at least one side of the paper (95;95a);
creating the at least one fold line (40,45;40a,45a) extending across the width of
the sheet of paper (95;95a) between the first and second panels (92,94;99,97); and
generating the perforated line (35,50;35a,75) extending across the width of the paper
(95;95a) such that the first panel (92;99) can be separated from the paper (95;95a).
11. The method of claim 10, further comprising generating a second perforated line (50).
12. A method of creating an integrated bidirectional mailpiece having outgoing and return
envelope functionality, the method comprising steps of:
providing an article of manufacture one of claims 1 to 9;
folding the paper (95;95a) along the fold lines (40,45;40a,45a) to form the mailpiece
such that the first address (87) on the first panel (92;99) is viewable on an exterior
of the mailpiece, and the second address (85) on the second panel (94;97) is concealed
in an interior of the mailpiece; and
sealing the folded paper along one or more of the first, second or third adhesive
portions (10,20,22,30,32,60; 10a,20a,22a,30a,32a,60a) positioned along one or more
surfaces of the mailpiece.
13. The method of claim 12, wherein providing the article of manufacture comprises:
receiving a continuous web of pre-printed paper from a paper stock (140), the pre-printed
paper containing the first address (87) for the outgoing envelope in the first panel
(92;99) and the second address (85) for the return envelope in the second panel (94;97);
applying the at least one first adhesive region (10;10a) to a surface of at least
one side of the paper (95;95a);
creating the at least one fold line (40,45;40a,45a) extending across the width of
the paper (95;95a) between the first and second panels (92,94;99,97); and
generating the perforated line (35,50;35a,75) extending across the width of the paper
(95;95a) such that the first panel (92;99) can be separated from the paper (95;95a).
14. The method of claim 13, wherein the printing step includes:
printing a coupon or an advertisement on the paper (95;95a) and/or instructions for
opening the outgoing envelope and assembling the return envelope.
15. The method of one of claims 12 to 14, further comprising the step of:
inserting one or more pages of assembled inserts (120-123) to be included inside the
mailpiece.
16. The method of one of claims 12 to 15, further comprising the step of forming a perforation
across the formed mailpiece.
17. The method of one of claims 10 to 12, further comprising the step of cutting the formed
mailpiece from the continuous web of pre-printed paper.
18. A system for generating a bidirectional integrated mailpiece (170) having outgoing
and return envelope functionality, the system comprising:
a printer (333) configured to print information on at least one side of paper (95;95a),
the paper (95;95a) including a first address (87) on a first panel (92;99) for the
outgoing envelope and a second address (85) on a second panel (94;97) for the return
envelope, the second address (85) being different from the first address (87);
a wrapping document processing system (100), containing:
a glue applicator configured to apply one or more adhesive regions (10,20,22,30,32,60;10a,20a,22a,30a,32a,60a)
on at least one side of the paper (95;95a);
a perforator configured to create a perforated line (35,50;35a,75) extending across
a width of the paper (95;95a) between the first and second panels (92,94;99,97); and
a folder configured to fold paper along one or more fold lines (40,45;40a,45a) such
that the first address (87) on the first panel (92;99) is viewable on an exterior
of the mailpiece, and the second address (85) on the second panel (94;97) is concealed
in an interior of the mailpiece.
19. The system according to claim 15, further comprising:
one or more insertion feeders (135,136) for feeding one or more pages of inserts (120-123)
to be included inside the mailpiece,
wherein the folder configured to fold the paper (95;95a) along the one or more fold
lines such that the one or more inserts (120-123) are wrapped within the mailpiece.