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[0001] The direct mail industry has historically utilized envelopes with single pockets for automated insertion of mailing components. In the past, mailing components historically have only included paper or like materials. To maximize efficiency, the direct mail industry has utilized automated machine-based processes for preparing mailings, including inserting materials, sealing, and addressing the envelopes and applying postage. However, with the rapid growth of Internet usage and personal computing at the household level, there is a growing necessity to mail outnumbers of electronic and optical media discs and devices to be included in direct mailers. Most of the computers being used by consumers at the household level, whether PC or Macintosh, are installed with optical media disc drives, which can read from and wrote onto removable media discs of various formats. These formats include the ubiquitous CD-ROM format, as well as the increasingly utilized CD-R, CD-RW, DVD-ROM, DVD-R, DVD-RW, DVD+RW formats, as well as compact discs of other removable media types. Currently there is a growing need felt by the direct mail industry for a means to prepare and deliver, in a cost effective automated insertion manner removable media and/or plastic media included with paper inserts or like materials through the mail to consumers. This is being driven by the growing awareness among Direct Mail marketers of the advantages of mailed removable media discs as sales and marketing vehicles. These advantages stem mainly from 1) the large capacity of such discs, such as CDROM and DVDROM discs, and 2) their ability to function dynamically as two-way communication devices. A description of these advantages is in order.
[0002] The digital capacity of a standard 12 cm CDROM disc, for example, is close to 700 megabytes. With this capacity, a marketer can advertise a product with over 60 minutes of video and thousands of pages of high-quality graphics and text. In other words, a marketer could place an entire catalogue on such a disc, use only the highest quality graphics, and support each product and/or service with video vignettes. The capacity would be even larger for a DVDROM disc. For the same marketer to mail the equivalent content without the benefit of such a disc, one or more bulky VHS tapes would be required, along with one or more thick and fairly heavy catalogues. All combined, the mailer without the disc would likely be impractically large and would incur a significantly higher postage rate.
[0003] The other main advantage of removable media discs is their ability to dynamically capture data. The same CDROM disc described above would be able to connect to the Internet via an Internet connection on the computer in which it is played. The marketer could therefore generate e-commerce sales and collect valuable marketing data from the consumer without the need and costs associated therewith for 1-800 number support or pre-printed reply/mail-in cards.
[0004] With the above advantages considered, the reader may presume there has been an explosion of Direct Mail that incorporates removable media. This has not, however, been the case. The reason for this is the relative newness of the removable media as sales and marketing devices, to which the Direct Mail industry has not yet reacted.
[0005] There is also a need in the Direct Mail industry for additional printable “real estate” or surfaces of envelopes to enhance the ability of advertisers to get their message across. Advertisers for years have used traditional printed paper media in their direct mail advertising campaigns. Advertisers have balked, however, at utilizing optical media solely in their advertising campaigns because of the perception that if the recipient does not place the optical media in their computer, the advertiser's message has not been delivered. Advertisers perceive a need, therefor, to combine printed paper media with optical media in their advertising campaigns so as to assure their advertiser's message is delivered.
[0006] Current service providers and original equipment manufacturers in the direct mail industry offer few, if any, options for direct mailers to keep up with technological advances by incorporating removable media, such as optical media discs. The direct mailing processes include inserting of objects into envelopes, ink jet printing on the envelopes, sealing the envelopes, and applying postage. These traditional activities do not accommodate removable media discs, using direct mail equipment. The processes do not support the use of removable media discs in the same automated manner. For example, the current insertion machines that automate the direct mailing processes, such as that described and disclosed in U.S. Pat. No. 4,955,185 (hereinafter the '185 patent), are not designed for removable media disc insertion into envelopes typically used in direct mail. The result is that service providers in the direct mail industry have to employ manual labor, such as hand insertion, in order to fulfill customer requests for mailers that incorporate removable media such as optical media discs. Moreover, the typical mailers and envelopes themselves, such as the #10 regular, #10 window, #9, 6×9 window, 6×9 regular, 9×12 catalog, 9×12 booklet, and others, unless otherwise custom ordered, are not of a paper weight to prevent the mailer from bending around the edges of the housed disc. These sizes also do not offer a pocket in which media can be automatically placed and in which the disc is protected from breaking, scratching or cracking. The heavier paper stocks, additional materials, and required hand labor for Direct Mail campaigns that incorporate removable media discs, together translate into pronounced higher costs.
[0007] There does exist holders in which optical media and print media is hand inserted. Such holders are used in the photo developing industry to provide prints to customers along with an optical disc on which is stored the customer's pictures. These holders are not suited for direct mail purposes because they are not compatible with present automatic paper insertion equipment, nor does equipment exist to accomplish the automatic insertion of the desired optical media into a direct mail envelope along with other marketing media. Additionally, these holders, because they position the optical disc at the edge of the holder, do not protect the optical disc sufficiently to assure their safe processing and delivery by the postal service.
[0008] Presently, it is possible in the optical media market to insert industry standard 12 cm and 8 cm discs by machine. However, the machinery used in this industry, such as that disclosed and described in U.S. Pat. No. 5,875,614 (hereinafter referred to as the '614 patent), only support the automated insertion of industry standard discs into a limited number of sleeve sizes. The vast majority of these sleeve sizes are of the 5 in.×5 in. variety such as the 5¼ in.×5 in., 5⅝ in.×5{fraction (1/32)} in., 5¼ in.×5¼ in., 5¼ in.×5{fraction (5/16)} in. size and others. These sleeves function as a protective carrier for optical media discs, and are not typically used as direct mail mailers. These sleeves do not provide sufficient “real estate” to get an advertiser's message across, nor do these sleeves provide the opportunity for sending marketing media, in a automated, single-pass manner. Such sleeves are constructed from stock which is too flimsy to protect discs from the hazards of mailing through the postal service. Furthermore, because sleeves are invariably manufactured in the two sizes mentioned above, marketers are given few options for size and configuration for direct mail campaigns that incorporate removable media discs. Further complications arise in that these sleeves, when used as mailers or envelopes, are not automation compatible with current postal service requirements, and must be processed in a manner that requires higher postage charges than conventional mailers.
[0009] The existing machinery and inline single-pass machine processes used in the direct mail industry do not currently support removable media discs. Conversely, the existing machinery and machine processes used in the optical media industry currently do not support the multitude of different envelope sizes and configurations used in the direct mail industry nor can they include paper inserts to accompany the media. Therefore, mailings that incorporate removable media inserts, such as optical discs, typically incur a much higher cost than those mailings that do not incorporate removable media inserts.
[0010] For these reasons, there is a need for a mailer that can accommodate the direct mailing of different types of media, processed in a single-pass automated manner and sent together in one mailer, i.e. removable media, and plastic media, and paper or like materials. There is also a need for direct mailing equipment and processes which provide for the automated single-pass insertion of different types of media together in one mailer, i.e. removable media, discs, plastic media, and paper or like materials.
[0011] All publications, including patent documents, referred to in this application are incorporated by reference in their entirety for all purposes. All headings are provided for the convenience of the reader and should not be used to limit the meaning of the text that follows the heading, unless so specified.
[0012] The present invention relates to a multiple pocket envelope, and to related methods and equipment for automatic insertion of media therein that satisfies the aforementioned needs. More specifically, the envelope has two pockets that are adjacent, separated by a common wall. The pockets are arranged in a manner so that the rear wall of the outer pocket is the front wall of the inner pocket. The entire envelope is formed from a unitary blank, that can be pre-printed and converted in customizable design and size configurations well known in the envelope converting field. This envelope provides extra printable “real estate” on the walls of the two pockets. The envelope is formed by folding, fastening, and optionally sealing the sides of the unitary blank.
[0013] The rear panel of the envelope is generally rectangular and has four sides that are defined by fold lines for four other integrally connected panels of the envelope which are defined as the two opposing side panels, the top panel and the bottom panel. The rear panel has both an inside and an outside surface as defined by the final configuration of the envelope. There are two opposed side panels that are integrally connected or joined to the rear panel, along the fold lines, and which are folded over to form an inner pocket leaving a portion of the rear panel inside surface uncovered or exposed and the edges or “buckles” of the opposed side panels “kiss” or touch each other. Optionally, the side panels overlap and are connected together at one or more glueable areas located on the buckles or on the panels. The inner pocket so formed has its mouth near the upper edge of the inside rear panel. The bottom panel is folded over and connected to the two opposed side panels at two glueable areas located on the lower panel to form an outer pocket suitable for insertion of removable media or other inserts. The bottom panel partially covers the folded opposed side panels and forms an outer pocket suitable for the insertion of removable media or other inserts. This outer pocket similarly has a mouth that is near the upper edge of the inside of the rear panel. The top panel is folded over the inner and outer pockets and acts to seal the inner and outer pockets. The top panel partially covers the bottom panel upon folding. Similarly, flaps of the inner pocket can be connected to the inside of the rear panel to form an inner pocket suitable for insertion of removable media or other inserts. Removable discs can, thus, optionally be inserted into the inner pocket and the printed inserts inserted into the outer pocket. Windows can optionally be included in either or both the bottom and rear panels to expose additional “real estate” on the inserted media to show through on the face of the envelope.
[0014] The method relates to a means of inserting media inside of an envelope, in an inline, single-pass, automated process. More specifically, the method includes a means for feeding an envelope, a means for feeding media to be inserted into the envelope, and inserting the media into the envelope.
[0015] The related equipment comprises a means for moving an envelope on or through the equipment. Furthermore, the equipment includes a means for feeding an envelope with one or more pockets onto the moving means. The equipment also includes a means for conveying the media, and for feeding the media towards the envelope on the moving means. The equipment also provides a means for inserting the media inside the envelope pocket or pockets. Finally the equipment provides a means for connecting with and between the moving means, the envelope and media feeding means, the conveying means, and the inserting means so that the equipment operates in a coordinated fashion.
[0016] The principal objects of the present invention are: to provide a dual pocket envelope; to provide a dual pocket envelope with additional printable “real estate”; to provide such an envelope which is adapted for use with automatic mail insertion equipment; to provide a method of insertion with such automatic mail insertion equipment; to provide automatic mail insertion equipment to accomplish automatic insertion of media into envelopes, to provide such an envelope which is well adapted for use with automatic mail processing equipment; to provide such an envelope that is adapted for in line, single-pass automated insertion with a plurality of media inserts; and to provide such an envelope that is particularly well adapted for use with optical and other removable media inserts. Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, embodiments of this invention.
[0017] The drawings constitute apart of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024] Definitions
[0025] “Connecting” means a method for fastening, including but not limited to the use of booger glue, rewettable glue, or glue strip.
[0026] “Envelope” refers to an envelope already containing inserted media or, alternatively, an envelope devoid
[0027] “Media” means a type of material that can be inserted into and is otherwise removable from an envelope, including removable media defined herein, whether the material is (1) traditional paper or like materials or (2) electronic media, or optical media discs, or other computer-readable object, or equivalent; (3) plastic media such as credit cards, identification cards or related cards.
[0028] “Perforated” refers to any structurally weakened area or line. The weakening of this area or line can be accomplished by scoring, punching, folding, embossing or other like method.
[0029] “Unitary blank” means a single completely intact cut sheet of paper that is converted into an envelope.
[0030] “Business reply card” means a paper unit that can be removed from the envelope along a perforated line and separately filled out and mailed to a pre-printed address, or a coupon with pre-printed information, or other such equivalent.
[0031] “Removable media” means any type of electronic media such as optical discs, magnetic discs, magneto-optical discs, solid-state memory discs, discs of other formats, memory cards, memory sticks, or any other computer-readable storage object.
[0032] “Optical media” means discs removable discs of the various optical media formats, such as, but not limited to, CD-ROM, CD-R, CD-RW, CD-Video, DVD-Video, DVD-ROM, DVD-RAM, DVD-R DVD-RW, DVD+RW, DVD-R/CD-RW combo, DVD-RW/CD-RW combo, or other like equivalent.
[0033] “Suction cup” means a vacuum-operated pickup head which generates a suction force at its surface area that is calibrated to firmly pick up or move media, envelopes, or envelope panels. The suction cup is enabled by a motorized air compressor.
[0034] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in varying forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0035]
[0036] With reference to
[0037] The side panels
[0038] Alternatively the side panels
[0039] Bottom panel
[0040] Top panel
[0041] The outer pocket can be sealed, or fastened in a manner as to allow a person to unseal or unfasten the envelope, exposing the materials therein, and allow a person to view the inside of bottom panel
[0042] The envelope can additionally have an optional window as shown in
[0043]
[0044] The second media insertion station
[0045] The second media insertion station
[0046] The feeding chute
[0047] The pusher assembly
[0048] The moving means positions an envelope at lip
[0049] Upon insertion of media
[0050] Optionally, the second media insertion station
[0051] Additionally shown in
[0052] The entire second media insertion station
[0053] In one embodiment of the invention the insertion method occurs in steps. In another embodiment of the invention, one or more of the steps occur automatically. In another embodiment of the invention all the steps occur in a continuous stream. In a further embodiment the feeding steps occur in an automatic, continuous stream and in a step-wise movement. In again another embodiment of the invention, after the insertion of the media inside the envelope there is a step to verify proper insertion of the media inside the envelope. In a further embodiment, an address or like data is printed on the outside face of the envelope before the insertion of said media of said envelope. Similarly, in another embodiment, an address or like data is printed on the media prior to being fed automatically and wherein said address or like data corresponds to an address or like data printed on the outside face of the envelope. In one optional embodiment, an unillustrated printing mechanism prints an address or like data on the outer surface of the envelope after insertion of the media.
[0054] A dual pocket envelope is fed into the envelope insertion station
[0055] An air suspension system creates an air cushion through a plurality of vents
[0056] To begin the movement of the optical media disc, the feeding piston
[0057] The moving means positions the envelope at lip
[0058] Prior to reaching the envelope sealing/receiving station
[0059] Next, after passing through the sealing structure
[0060] It is to be understood that while certain forms of the present invention have been illustrated and described herein, the present invention is not to be limited to the specific forms or arrangement of parts described and shown.