DOUBLE ENVELOPE FOR STANDARD PRODUCTION PRINTING

Abstract

A method and apparatus includes/uses a media supply that maintains the media sheets and a printing engine that places markings on the sheets. The media sheets have multiple opposing partially formed envelopes. The markings placed have opposite orientations on the opposing envelopes. The apparatus also optionally includes a separator that separates the opposing partially formed envelopes after the printing engine places the marking, to leave partially formed individual envelopes. A folder device optionally folds the partially formed individual envelopes to produce completed individual envelopes.

Description

BACKGROUND SUMMARY

Embodiments herein generally relate to electrostatographic printers and copiers or reproduction machines, and more particularly, concern a system and method of printing small envelopes, and more particularly, to systems and methods that use media sheets that have multiple opposing partially formed envelopes.

Many companies are interested in providing customers with standard, low cost small envelopes (such as #10 envelopes) that can be easily processed through existing printing production products. Standard “off the shelf” #10 envelopes are only 4.125″ long. Standard nip spacing in a paper path of a printing device can be about 165 mm long (6.5″). Transporting such small envelopes through a paper path would require much closer nip spacing than the current standard nip spacing resulting in increased cost, power, and noise if printing products were manufactured to have smaller nip spacing. Feeding and stacking design would also see significant impacts in cost, power, and noise if they were redesigned to handle small envelopes, since they are not currently designed to feed or stack papers of such a small size.

Therefore, the following disclosure presents a system and method that utilizes a sheet that has a “double envelope” which is intended to be die cut and folded to produce pairs of individual envelopes having the same dimensions as a standard #10 envelope. As explained in greater detail below, with embodiments herein, the two envelopes are joined together along the top edge of the envelope flap. Before being separated from one another, the pairs of envelopes are mirror images of each other. Therefore, the printing process prints addresses and/or other information in a proper orientation for each individual envelope (that are upside down with respect to one another) since the envelopes face opposite each other. After printing, the envelopes are separated (die cut) to leave two separate envelopes.

Embodiments herein include a method of printing small envelopes, such as #10 envelopes. The method supplies media sheets that have multiple opposing partially formed envelopes using a roller nip based sheet feeding system. If the individual envelopes were fed into the sheet feeding system, they would be too small because the sheet feeding system has nip spacing larger than the individual envelopes. Therefore, embodiments herein use media sheets that are large enough for the nip spacing, and that have such multiple opposing partially formed envelopes.

Once the sheets are supplied, the method places markings on the sheets of the opposing partially formed envelopes. Because the partially formed envelopes oppose one another, the markings have opposite orientations. Saying the markings have “opposite orientations” means that the markings have a first orientation and a second orientation that is upside down with respect to the first orientation.

After printing, the method separates the opposing partially formed envelopes to leave partially formed individual envelopes. The media sheets have a separating line between pairs of the opposing partially formed envelopes and the method separates the media sheets along the separating line. The partially formed individual envelopes are then folded to produce completed individual envelopes. Also, the folding process folds a panel of the partially formed individual envelopes bordering the separating line toward the center of the partially formed individual envelopes to put the envelopes in final form (completed individual envelopes).

This disclosure also presents apparatus embodiments that include a media supply that maintains the media sheets and a printing engine that places markings on the sheets. Again, such markings have opposite orientations on the opposing envelopes of the sheets. The apparatus also includes a separator (cutter or dicer) that separates the opposing partially formed envelopes after the printing engine places the marking, to leave partially formed individual envelopes. The separator divides the media sheets along the separating line.

A folding device (folder) folds the partially formed individual envelopes to produce the completed individual envelopes. The folder device folds a panel of the partially formed individual envelopes bordering the separating line toward the center of the partially formed individual envelopes to put the envelopes in final form (completed individual envelopes).

A roller nip based sheet feeding system provides a sheet path between the media supply, the printing engine, the separator, and the folder. Again, the sheet feeding system has nip spacing larger than the size of the individual envelopes. Therefore, embodiments herein use media sheets that are large enough for the nip spacing, and that have such multiple opposing partially formed envelopes.

These and other features are described in, or are apparent from, the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of the systems and methods are described in detail below, with reference to the attached drawing figures, in which:

FIG. 1 is a flowchart illustrating method embodiments herein;

FIG. 2 is a top-view schematic diagram of a multi-envelope sheet according to embodiments herein;

FIG. 3 is a top-view schematic diagram of a multi-envelope sheet separated into individual envelopes according to embodiments herein;

FIG. 4 is a top-view schematic diagram of a multi-envelope sheet separated into individual envelopes according to embodiments herein;

FIG. 5 is a top-view schematic diagram of a multi-envelope sheet according to embodiments herein;

FIG. 6 is a top-view schematic diagram of a multi-envelope sheet having print markings according to embodiments herein; and

FIG. 7 is a schematic diagram of system embodiments herein.

DETAILED DESCRIPTION

As mentioned above, many companies are interested in providing customers with standard, low cost small envelopes that can be easily processed through existing printing production products. However, transporting such small envelopes through a paper path would require much closer nip spacing than the current standard nip spacing resulting in increased cost, power, and noise if printing products were manufactured to have smaller nip spacing. Feeding and stacking design would also see significant impacts in cost, power, and noise if they were redesigned to handle small envelopes.

Therefore, as shown in flowchart form in FIG. 1, the method works with a printing system in items 100-102 and works with inline or offline finishing in items 104-110. The method supplies media sheets that have multiple opposing partially formed envelopes using a roller nip based sheet feeding system in item 100. Embodiments herein print on small envelopes, such as #10 envelopes (or any sized envelope such as a #1, #2, #3 . . . #99, etc. size envelope). While one specific envelope size (e.g., #10 envelopes) is mentioned herein, those ordinarily skilled in the art would understand that the embodiments herein are applicable to any appropriately sized envelope that is too small for the equipment (sheet feeding trays, nip rollers, finishing units, etc.) on which such envelopes will be printed. Therefore, the embodiments herein are not limited to the specific envelope sizes that are discussed herein and are useful with all different sized and shaped envelopes.

Thus, one feature of the embodiments herein is that they are useful with envelopes of any size and shape that are too small for the processing equipment to which they are being supplied. If the individual envelopes were fed into the sheet feeding system, they would be too small because the sheet feeding system has nip spacing larger than the individual envelopes. Therefore, embodiments herein use media sheets that are large enough for the nip spacing, and that have such multiple opposing partially formed envelopes.

More specifically, referring to FIG. 2, one exemplary media sheet 200 is illustrated that includes two separate envelopes 220, 222. Each of the envelopes includes side flaps 202 and a bottom flap 204. Item 206 represents a fold line, item 208 represents a separation line, and item 210 represents some form of adhesive or bonding structure (moisture-activated adhesive, peel back self-adhesive, physical clipping/hooking structures, etc.). The fold line 206 and separation line 208 are not actual printed lines, but instead represent locations where folds and cuts will be made, as shown in greater detail below.

The sheet designs shown in FIGS. 2-6 were not generally known before the present invention; however the methods and materials used to create such multi-envelope sheets are well known to those ordinarily skilled in the art. To create such multi-envelope sheets, sheets of paper are cut, folded, and glued to create the opposing partially formed envelopes that are illustrated in FIGS. 2-6. While the embodiments herein are not limited to the specific design shown in FIGS. 2-6, such sheets could be formed by cutting a sheet of paper to include the side flaps 202 and the bottom flaps 204. The side flaps 202 could then be folded inward, the bottom flaps 204 could be folded inward, and the bottom flaps 204 could be adhered (glued, bonded, etc.) to the side flaps 202.

The details regarding different ways to make envelopes, different types of folds, different types of paper cutters, different types of adhesives, etc. are well known to those ordinarily skilled in the art is shown for example by U.S. Pat. Nos. 6,845,864; 5,887,780; 5,050,812; 4,807,805; 4,071,997; and 761,912 (the complete disclosures of which are incorporated herein by reference) and such structures and processes are not discussed in detail herein.

Once the sheets are supplied in item 100 (FIG. 1), the method places markings on the sheets of the opposing partially formed envelopes in item 102. For example, FIG. 6 illustrates the opposite side of the sheet 200 shown in FIG. 2. The printing process in item 102 prints mailing addresses 602 and return addresses 604 of the opposite side of the sheet 200. Because the partially formed envelopes oppose one another, the markings 602, 604 placed in item 102 have opposite orientations, as shown in FIG. 6. Saying the markings have “opposite orientations” means that the markings have a first orientation (right side of FIG. 6) and a second orientation (left side of FIG. 6) that is upside down with respect to the first orientation.

After printing in item 102, the method separates the opposing partially formed envelopes in item 104 to leave partially formed individual envelopes shown by item 106. It is also possible that the printer may only print the double envelopes and that separation, folding, stuffing, and gluing may be done offline. This is also shown in FIG. 3 where, as discussed above, the method separates the media sheet 200 into two individual partially formed envelopes 300, 302 along the separating line 208.

The partially formed individual envelopes are then folded in item 108 to produce completed individual envelopes shown by item 110. As shown in FIGS. 3 and 4, this folding process 108 folds a panel 304 of the partially formed individual envelopes 300, 302 bordering the separating line 208 (FIG. 2) toward the center of the partially formed individual envelopes 300, 302 (as shown by the arching arrows in FIG. 3) to put the envelopes 300, 302 in final form (completed individual envelopes) as shown in FIG. 4. Therefore, the folding process in item 108 folds the top flaps 304 away from the separating line 208 and toward the center of each individual envelope 300, 302.

The flaps 304 are shown in their folded over position in FIG. 4; however, the adhesive 210 is not activated (is not moistened, is not exposed, etc.) so that the flaps 304 are only folded over, and are not bonded to the remaining flaps 202, 204 (until the adhesive 210 is activated by the user). Therefore, after the folding process in item 108, the user can still access the pocket created by flaps 202 and 204 which allows the user to insert a letter or other item into the envelope before activating the adhesive 210 and sealing the envelope.

While dual envelope sheets 200 are discussed in the previous example, the embodiments herein can include any even number of envelopes depending upon the size of the envelope and the size of the sheet 200. For example, as shown in FIG. 5, the sheet 500 includes two pairs of opposing partially formed envelopes (one pair is shown by items 502 and 504 and another pair is shown by items 506 and 508). Those ordinary skilled in the art would understand that the sheet could include three pairs, four pairs, five pairs, etc., of envelopes, again depending upon the size of the envelopes and the size of the sheet 500.

As shown in FIG. 7, this disclosure also presents apparatus embodiments (system 700) that include a media supply 702 that maintains the media sheets 200, 500, etc. and a printing device 704 that places markings on the sheets. Again, such markings have opposite orientations on the opposing envelopes of the sheets. The apparatus also includes a separator 706 (cutter or dicer) that separates the opposing partially formed envelopes after the printing device 704 places the marking, to leave partially formed individual envelopes. The separator 706 divides the media sheets along the separating line. All such items shown in FIG. 7 are well-know as illustrated by the patents incorporated elsewhere herein, and the details of each device is not discussed herein; however, the use of the sheets 200, 500 with such components was not known previously.

A folding device (folder 708) folds the partially formed individual envelopes to produce the completed individual envelopes. The folder device 708 folds the panel 304 of the partially formed individual envelopes toward the center of the partially formed individual envelopes to put the envelopes in final form (completed individual envelopes).

A roller nip based sheet feeding system 710 provides a sheet path between the media supply 702, the printing device 704, the separator 706, and the folder 708. Again, the sheet feeding system 710 has nip spacing larger than the size (height) of the individual envelopes. For example, the height of one of the individual envelopes 302 is shown by the height measure H shown in FIG. 4. As shown in FIG. 7, this height measure H of the individual envelopes is smaller than the spacing S between two of the nips of the sheet feeding system 710, which prevents the individual envelopes from being utilized with the printing device 704. While the printing device 704 could be redesigned to include nips that are spaced closer together, such changes are very expensive. In order to address these issues, the embodiments herein use the opposing partially formed envelope media sheets 200, 500, etc. that are discussed above.

In addition, the printing engine 704 can include some form of processor 712 (central processing unit (CPU)) or other computerized device that can include a computer storage medium. Computerized devices that include chip-based central processing units (CPU's), input/output devices (including graphic user interfaces (GUI), memories, comparators, processors, etc. are well-known and readily available devices produced by manufacturers such as International Business Machines Corporation, Armonk N.Y., USA and Apple Computer Co., Cupertino Calif., USA. Such computerized devices commonly include input/output devices, power supplies, processors, electronic storage memories, wiring, etc., the details of which are omitted herefrom to allow the reader to focus on the salient aspects of the embodiments described herein. One feature of embodiments herein is that the processor 712 can automatically orient the printing as shown in FIG. 6. Therefore, with embodiments herein, the user only needs to supply the information that is to be printed on the envelope (mailing address, return address, postage, other remarks and data, etc.). The processor can recognize that the envelope media sheets 200, 500, etc. are being utilized and can automatically orient the printing as shown in FIG. 6, as discussed above, utilizing any macro or similar series of processing commands or steps (utilizing, for example, if-then statements). Thus, the orienting of the printed items shown in FIG. 6 is performed automatically and without additional a user intervention, which makes the embodiments herein seamless and easy to use.

Therefore, as shown above, the present embodiments provide a system and method that, in one example, utilizes a sheet that has a “double envelope” which is intended to be die cut and folded to produce pairs of individual envelopes (each having the same dimensions as a standard #10 envelope). With embodiments herein, the two envelopes are joined together along the top edge of the envelope flap. Before being separated from one another, the pairs of envelopes are mirror images of each other. Therefore, the printing process prints addresses and/or other information in a proper orientation for each individual envelope (that are upside down with respect to one another) since the envelopes face opposite each other. After printing, the envelopes are separated (die cut) to leave two separate envelopes.

Thus, the embodiments herein can, for example, provide an approximately 11″ long double envelope sheet which is easily fed, transported, and stacked in a standard production paper path. The width of the envelope is the same as a standard #10 envelope at 9.5″. Therefore, the embodiments herein can be used in machines that have paper trays, nip spacing, stacking trays, etc. that are currently designed to accommodate common paper sizes, such as A3; A4; 8½×11; 8½×14; etc.

The word “printer” or “image output terminal” as used herein encompasses any apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, etc. which performs a print outputting function for any purpose. The details of printers, printing engines, etc. are well-known by those ordinarily skilled in the art and are discussed in, for example, U.S. Pat. No. 6,032,004, the complete disclosure of which is fully incorporated herein by reference. The embodiments herein can encompass embodiments that print in color, monochrome, or handle color or monochrome image data. All foregoing embodiments are specifically applicable to electrostatographic and/or xerographic machines and/or processes.

It will be appreciated that the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. The claims can encompass embodiments in hardware, software, and/or a combination thereof. Unless specifically defined in a specific claim itself, steps or components of the invention should not be implied or imported from any above example as limitations to any particular order, number, position, size, shape, angle, color, or material.

Claims

1. An apparatus comprising:

a media supply maintaining media sheets, said media sheets comprising multiple opposing partially formed envelopes;

a printing engine placing markings on said sheets of said opposing partially formed envelopes, said markings having opposite orientations on opposing envelopes of said opposing partially formed envelopes;

a separator that separates said opposing partially formed envelopes after said printing engine places said marking to leave partially formed individual envelopes; and

a folder that folds said partially formed individual envelopes to produce completed individual envelopes.

2. The apparatus according to claim 1, said media sheets comprising a separating line between pairs of said opposing partially formed envelopes.

3. The apparatus according to claim 2, said separator dividing said media sheets along said separating line.

4. The apparatus according to claim 2, said folder folds a panel of said partially formed individual envelopes bordering said separating line toward a center of said partially formed individual envelopes.

5. The apparatus according to claim 1, said opposite orientations comprise a first orientation and a second orientation upside down with respect to said first orientation.

6. An apparatus comprising:

a media supply maintaining media sheets, said media sheets comprising pairs of opposing partially formed envelopes;

a printing engine placing markings on said sheets of said opposing partially formed envelopes, said markings having opposite orientations on opposing envelopes of said opposing partially formed envelopes;

a separator that separates said opposing partially formed envelopes after said printing engine places said marking to leave partially formed individual envelopes; and

a folder that folds said partially formed individual envelopes to produce completed individual envelopes; and

a roller nip based sheet feeding system providing a sheet path between said media supply, said printing engine, said separator, and said folder, said sheet feeding system having nip spacing larger than a size of said individual envelopes.

7. The apparatus according to claim 6, said media sheets comprising a separating line between pairs of said opposing partially formed envelopes.

8. The apparatus according to claim 7, said separator dividing said media sheets along said separating line.

9. The apparatus according to claim 7, said folder folds a panel of said partially formed individual envelopes bordering said separating line toward a center of said partially formed individual envelopes.

10. The apparatus according to claim 6, said printing engine comprising one of a electrostatographic and xerographic printing device.

11. A method comprising:

supplying media sheets comprising multiple opposing partially formed envelopes;

placing markings on said sheets of said opposing partially formed envelopes, said markings having opposite orientations on opposing envelopes of said opposing partially formed envelopes;

separating said opposing partially formed envelopes after said printing engine places said marking to leave partially formed individual envelopes; and

folding said partially formed individual envelopes to produce completed individual envelopes.

12. The method according to claim 11, said media sheets comprising a separating line between pairs of said opposing partially formed envelopes.

13. The method according to claim 12, said separating comprising dividing said media sheets along said separating line.

14. The method according to claim 12, said folding comprising folding a panel of said partially formed individual envelopes bordering said separating line toward a center of said partially formed individual envelopes.

15. The method according to claim 11, said opposite orientations comprise a first orientation and a second orientation upside down with respect to said first orientation.

16. A method comprising:

supplying media sheets comprising multiple opposing partially formed envelopes using a roller nip based sheet feeding system;

placing markings on said sheets of said opposing partially formed envelopes, said markings having opposite orientations on opposing envelopes of said opposing partially formed envelopes;

separating said opposing partially formed envelopes after said printing engine places said marking to leave partially formed individual envelopes; and

folding said partially formed individual envelopes to produce completed individual envelopes

said sheet feeding system having nip spacing larger than a size of said individual envelopes.

17. The method according to claim 16, said media sheets comprising a separating line between pairs of said opposing partially formed envelopes.

18. The method according to claim 17, said separating comprising dividing said media sheets along said separating line.

19. The method according to claim 17, said folding comprising folding a panel of said partially formed individual envelopes bordering said separating line toward a center of said partially formed individual envelopes.

20. The method according to claim 16, said opposite orientations comprise a first orientation and a second orientation upside down with respect to said first orientation.