MAILPIECES THAT MITIGATE FLEXURE OF HELD ARTICLES DURING AUTOMATED HANDLING
Mailpieces configured to mitigate flexure of frangible articles during handling by postal processing equipment. The mailpieces include spacers that intervene between the stress-sensitive article held by the mailer and a convex surface of a roller, drum, spindle, or other mechanical device used in the postal processing equipment for transporting the mailpieces.
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This application claims the benefit of U.S. Provisional Application No. 60/805,416, filed Jun. 21, 2006, the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTIONThe 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 INVENTIONMailpieces 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.
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.
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 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.
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.
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 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.
With reference to
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.
Mailpiece 22, which may have a generally rectangular shape, has a height, h, (
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
Frangible article 16 is typically carried inside mailpiece 22 with at least a portion of the hub 18 located 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 (
As best shown in
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 articles when handled by automated processing equipment of the type used by the United States Postal Service.
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 INVENTIONIn 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.
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.
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 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.
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.
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.
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.
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 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.
The invention may be used in conjunction with mailpieces shown and described in U.S. Pat. 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 DRAWINGSThe 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.
With reference to
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 (
Spacers 38a,b, and spacers 40a,b have a thickness, t1, 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 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, t1, 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 (
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 panel 42. 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.
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
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 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.
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 panel 42 contacts the roller 12. The spacers 38a,b, 40a,b are shaped and have a thickness, t1, 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.
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.
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, t1, 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, t1, 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, t1, 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.
With reference to
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 (
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.
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.
With specific reference to
With specific reference to
With reference to
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 panel 42 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
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 38c,d, 40c,d is incidental to the mitigation of the flexing of the article 16.
With reference to
With reference to
When belt pressure 28 (
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 panel 44 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.
With reference to
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 (
With reference to
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 38a,b, 40a,b (
With reference to
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 (
While the embodiment of
With reference to
While the embodiment of
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 (
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
With reference to FIGS. 13A,B in which like reference numerals refer to like features in
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.
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 panel 85 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 87 lies 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 (
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.
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 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.
With reference to FIGS. 13C,D in which like reference numerals refer to like features in
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.
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 arrangement of spacers 37c,d (
Article 16 may be placed within sleeve 100, which may in turn be inserted into mailpiece 23g (
With reference to
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 panel 85 either above or below the central axis 19 of article 16, while a second set of disks 105a,b is coupled to panel 87 on the opposite side of central axis 19. In the exemplary embodiment of
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 (
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 (
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.
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.
With reference to
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 (
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
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
With reference to
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 118a,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.
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
With reference to
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 (
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
With reference to
With reference to
Mailpiece 150 further 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 (
As best shown in
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 (
With reference to
With reference to
With reference to FIGS. 21A,B in which like reference numerals refer to like features in
With reference to
With reference to
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 117a, a back side 119a, a hub 18a, a center opening 21a, and a central axis 19a. Article 16a further includes annular spacers 170a,b that are concentric with center opening 21a 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 21a such that they do not interfere with the writing and reading of information respectively to and from a media region 20a of article 16a.
The annular spacers 170a,b may be adhesively bonded to the sides 117a, 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.
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 (
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.
Claims
1. A mailpiece for mailing an article having a first side and a second side opposite to the first side, the mailpiece comprising:
- a first panel;
- a second panel joined to said first panel to define a first peripheral edge, a second peripheral edge, and side edges connecting said first and second peripheral edges, said first and second panels disposed on the respective opposite sides of the article, and the article being positioned between said first and second edges;
- a first spacer carried by said first panel, said first spacer disposed between the first side of the article and said first panel; and
- a second spacer carried by said second panel, said second spacer disposed between the second side of the article and said second panel.
2. The mailpiece of claim 1 wherein at least one of said first and second spacers intersects at least one of said first and second side edges.
3. The mailpiece of claim 1 wherein each of said first and second panels has an inner surface confronting a respective one of the first and second sides of the article across a surface area, said surface area has a center, said first spacer is disposed between said center and said first edge, and second spacer is disposed between said center and said second edge.
4. The mailpiece of claim 1 wherein said each of said first and second panels has an inner surface confronting a respective one of the first and second sides of the article across a surface area, said surface area has a center, and said first and second spacers are disposed between said center and said first edge.
5. The mailpiece of claim 5 further comprising:
- a third spacer disposed between the second side of the article and said second panel, said third spacer aligned substantially parallel to said first and second peripheral edges, and said third spacer disposed between said center and said second edge.
6. The mailpiece of claim 1 wherein said first and second spacers further comprise elongated members coupled with a respective one of said first and second panels.
7. The mailpiece of claim 6 wherein said elongated members are adhesively bonded to the respective one of said first and second panels.
8. The mailpiece of claim 1 wherein said first and second spacers further comprise elongated adhesive bead members coupled with a respective one of said first and second panels.
9. The mailpiece of claim 1 wherein said first and second spacers further comprise a plurality of staples juxtaposed with each other in a row, each of said staples adapted to deform between an open position and a closed position coupled with a respective one of said first and second panels.
10. The mailpiece of claim 1 wherein said first and second spacers further comprise Z-folded sections formed in a respective one of said first and second panels.
11. The mailpiece of claim 1 wherein said first and second spacers further comprise a stack of laminated flat members coupled with a respective one of said first and second panels.
12. The mailpiece of claim 1 wherein each of said first and second spacers has a thickness sufficient to reduce flexing of the article when said one or said first and second panels is distorted to conform to a curved shape of a crowned roller.
13. The mailpiece of claim 1 further comprising:
- an article having a central axis disposed between said first and second spacers.
14. The mailpiece of claim 1 wherein said first and second spacers are aligned substantially parallel to said first and second peripheral edges.
15. A mailpiece for mailing an article having a first side and a second side opposite to the first side, the mailpiece comprising:
- a first panel;
- a second panel joined to said first panel to define a first peripheral edge, a second peripheral edge, and side edges separating said second peripheral edge from said first peripheral edge; and
- a sleeve carrying the article, said sleeve disposed between said first and second panels, and said sleeve positioned between said first and second edges, said sleeve including a first spacer disposed between the first side of the article and said first panel, and a second spacer disposed between the second side of the article and said second panel.
16. The mailpiece of claim 15 wherein said first and second spacers are aligned substantially parallel to said first and second peripheral edges.
17. The mailpiece of claim 15 wherein each of said first and second spacers further comprise an aperture defined in said sleeve and a flap folded about an edge bordering said aperture.
18. The mailpiece of claim 15 wherein each of said first and second spacers further comprises an aperture defined in said sleeve and a member coupled with said aperture, said member having a thickness sufficient to reduce flexing of the article when said one or said first and second panels is distorted to conform to a curved shape of a crowned roller.
19. The mailpiece of claim 15 wherein each of said first and second spacers further comprises at least one raised feature coupled with said insert and projecting toward the article.
20. A mailpiece for mailing an article having a first side and a second side opposite to the first side, the mailpiece comprising:
- a first panel;
- a second panel joined to said first panel to define a first peripheral edge, a second peripheral edge, and side edges separating said second peripheral edge from said first peripheral edge, said first and second panels disposed on the respective opposite sides of the article, and the article being positioned between said first and second edges; and
- an insert between said first and second panels, said insert including a first spacer disposed between the first side of the article and said first panel and a second spacer disposed between the second side of the article and said second panel.
21. The mailpiece of claim 20 wherein said first and second spacers are aligned substantially parallel to said first and second peripheral edges.
22. The mailpiece of claim 20 wherein said insert comprises a sheet having a first end proximate to said first peripheral edge and a second end proximate to said second peripheral edge, said first spacer further comprises a first folded section of said sheet at said first end, and said second spacer further comprises a second folded section of said sheet at said second end.
23. The mailpiece of claim 22 wherein said sheet is folded such that said first and second ends are juxtaposed.
24. A mailpiece for mailing an article having a first side and a second side opposite to the first side, the mailpiece comprising:
- a first panel;
- a second panel joined to said first panel to define a first peripheral edge, a second peripheral edge, and side edges separating said second peripheral edge from said first peripheral edge, said first and second panels disposed on the respective opposite sides of the article, and the article being positioned between said first and second edges;
- a first insert between said first and second panels, said first insert including a first spacer disposed between the first side of the article and said first panel; and
- a second insert between said first and second panels, said first insert including a second spacer disposed between the second side of the article and said second panel.
25. The mailpiece of claim 24 wherein said first and second spacers are aligned substantially parallel to said first and second peripheral edges.
26. A mailpiece for use with 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 comprising:
- a first panel;
- a second panel joined to said first panel to define a first peripheral edge, a second peripheral edge, and side edges separating said second peripheral edge from said first peripheral edge, said first and second panels disposed on the respective opposite sides of the article, and the article being positioned between said first and second edges; and
- a spacer adapted to be inserted into the center opening of the article, and the spacer at least partially disposed between the first side of the article and said first panel.
27. The mailpiece of claim 26 wherein said spacer includes a hub region diametrically smaller than the center opening and a first flange portion diametrically larger than the center opening, said hub region disposed inside said center opening, and said first flange portion disposed between the first side of the article and said first panel.
28. The mailpiece of claim 27 wherein said spacer includes a second flange portion diametrically larger than the center opening, said second flange portion disposed between the second side of the article and said second panel.
29. The mailpiece of claim 27 wherein said spacer has a length greater than a thickness between the first and second sides of the article.
30. The mailpiece of claim 26 wherein said spacer includes a hub region disposed inside said center opening, said hub region diametrically smaller than the center opening such that said article is freely rotatable about said hub region.
31. The mailpiece of claim 26 wherein said spacer is carried by said first panel.
32. An apparatus for use with a mailpiece, the apparatus comprising:
- a frangible article having a first side and a second side opposite to the first side; and
- a first spacer projecting from said first side of said frangible article, said first spacer adapted to be disposed between said first side of said frangible article and the mailpiece.
33. The apparatus of claim 32 wherein said frangible article includes a central axis and a center opening about said central axis, and said first spacer is concentrically arranged relative to said central axis.
34. The apparatus of claim 32 wherein said frangible article includes a media region and a hub region arranged concentrically with said central axis, said hub region disposed radially between said media region and said center opening, and said hub region carrying said first spacer.
35. The apparatus of claim 34 wherein said frangible article includes a center opening extending through said hub region, and said first spacer is concentrically arranged relative to said center opening.
36. The apparatus of claim 32 wherein said first spacer is symmetrical with respect to said center opening so that the weight distribution of said frangible article is balanced.
37. The apparatus of claim 32 wherein said frangible article is round.
38. The apparatus of claim 32 further comprising:
- a second spacer projecting from said second side of said frangible article, said second spacer adapted to be disposed between said second side of said frangible article and the mailpiece.
Type: Application
Filed: Dec 14, 2006
Publication Date: Aug 9, 2007
Applicant: Butler Business Services, Inc. (Hamilton, OH)
Inventor: Todd Butler (Cincinnati, OH)
Application Number: 11/610,675
International Classification: B65D 27/00 (20060101);