Mailer, method and device for automatically inserting media therein

Abstract

A dual pocket envelope capable of receiving multiple inserts, including optical media. A method of insertion and related equipment for introducing inserts and media therein. The envelope is formed from a single sheet, customizable in size and shape. The single sheet is folded and fastened to create the dual pocket envelope. Optical media and other inserts are placed in the envelope in a step-wise manner, using a novel insertion equipment.

What is claimed is as follows:  
     
         1 . A multiple pocket envelope made from a unitary blank and comprising; 
 (a) a generally rectangular rear panel defined on the top, left, right and bottom sides by fold lines said rear panel having an inside and outside surface;    (b) a set of opposed side panels each of said side panels being integrally joined to said rear panel along one of said fold lines and being folded along into an overlying relation with the inside surface of said rear panel, said side panels being of such a size and shape as to partially cover said rear panel inside surface and to have their free side edges spaced a distance from each other so that a portion of the inside surface of the rear panel is exposed there between, and said opposed side panels form an inner pocket having a mouth near the upper edge of said inside surface of rear panel;    (c) a bottom panel, integrally joined to said rear panel along the said bottom side fold line and being folded along said fold line into an overlying relation with said opposed side panels, said bottom panel being of such size and shape as to partially cover said opposed side panels, and said bottom panel forming an outer pocket having a mouth near the upper edge of said rear panel inside surface;    (d) a means for connecting said bottom panel to said side panels;    (e) a top panel, integrally joined to said rear panel along said top side fold line and being folded along into an overlying relation with said bottom panel, said top panel being of such size and shape as to partially cover said bottom panel, and said top panel enclosing the said inner and outer pockets and covering said mouths; and    (f) a means for connecting said top panel to said bottom panel.    
     
     
         2 . The multiple pocket envelope as set forth in  claim 1 , further characterized by said side panels comprising a size and shape as to substantially cover said rear panel inside surface and to have their free side edges touching so that no portion of the inside surface of the rear panel is exposed there between.  
     
     
         3 . The multiple pocket envelope as set forth in  claim 1 , further characterized by said side panels comprising a size and shape as to totally cover said rear panel inside surface and to have their free side edges touching so that no portion of the inside surface of the rear panel is exposed there between.  
     
     
         4 . The multiple pocket envelope as set forth in  claim 1 , further characterized by said bottom panel comprising a size and shape as to substantially cover said opposed side panels.  
     
     
         5 . The multiple pocket envelope as set forth in  claim 1 , further characterized by said bottom panel comprising a size and shape as to totally cover said opposed side panels.  
     
     
         6 . The multiple pocket envelope as set forth in  claim 1 , further characterized by said top panel comprising a size and shape as to partially cover said bottom panel.  
     
     
         7 . The multiple pocket envelope as set forth in  claim 1 , further characterized by said top panel comprising a size and shape as to totally cover said bottom panel.  
     
     
         8 . The multiple pocket envelope as set forth in  claim 1 , further characterized by a window in said bottom flap which reveals the contents of the outer pocket.  
     
     
         9 . The multiple pocket envelope as set forth in  claim 1 , further characterized by a window in said back flap which reveals the contents of the inner pocket.  
     
     
         10 . The multiple pocket envelope as set forth in  claim 1 , further characterized by either or both side panels comprise a perforated line, wherein a portion or all of said side panels can be detached at said perforated line.  
     
     
         11 . The multiple pocket envelope as set forth in  claim 10 , wherein the detachable portion of the side panel is a business reply card.  
     
     
         12 . The multiple pocket envelope as set forth in  claim 1 , further characterized by a semicircular recess along the edge of the bottom panel.  
     
     
         13 . A method for inserting media inside of an envelope, said method comprising in sequence the operations of: 
 (a) feeding an envelope,    (b) sequentially feeding media to be inserted inside said envelope,    (c) inserting said media inside the envelope.    
     
     
         14 . The method of  claim 13 , wherein one or more of the steps occurs automatically.  
     
     
         15 . The method of  claim 13 , wherein either or both of the feeding steps occur in a stepwise motion.  
     
     
         16 . The method of  claim 13 , wherein all the steps occur in a continuous stream.  
     
     
         17 . The method of  claim 13 , wherein the feeding steps occur in an automatic, continuous stream and in a stepwise movement.  
     
     
         18 . The method of  claim 13 , wherein after the insertion of the media inside the envelope there is the step of verifying the proper insertion of said media inside of said envelope.  
     
     
         19 . The method of  claim 13 , wherein an address or like data is printed on the outside face of the envelope after the insertion of said media inside of said envelope.  
     
     
         20 . The method of  claim 13 , wherein an address or like data is printed on the outside face of the envelope before the insertion of said media inside of said envelope.  
     
     
         21 . The method of  claim 13 , wherein an address or like data is printed on the media prior to being fed automatically.  
     
     
         22 . The method of  claim 13 , wherein 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.  
     
     
         23 . Equipment for inserting media inside envelopes, said equipment comprising; 
 (a) a means for moving an envelope;    (b) a means for feeding an envelope onto said moving means;    (c) a means for conveying said media;    (d) a means for feeding said media towards said moving means;    (e) a means for inserting said media inside the envelope;    (f) a means for operatively connecting to and coordinating with and between said moving means, said envelope and media feeding means, said conveying means, and said inserting means.    
     
     
         24 . The equipment of  claim 23 , wherein said moving, envelope and media feeding, conveying and inserting means occurs in a stepwise fashion.  
     
     
         25 . The equipment of  claim 23 , wherein said envelope moving means moves a continuous supply of envelopes stepwise.  
     
     
         26 . The equipment of  claim 23 , wherein said envelope feeding means feeds a continuous supply of envelopes.  
     
     
         27 . The equipment of  claim 23 , wherein said media feeding means feeds a continuous supply of media.  
     
     
         28 . The equipment of  claim 23 , wherein a printing means prints an address or like data on the media prior to feeding.  
     
     
         29 . The equipment of  claim 23 , wherein said means for operatively connecting to and coordinating with and between said moving means, said envelope and media feeding means, said conveying means, and said inserting means is also connected to and coordinated with and between said printing means.  
     
     
         30 . A multiple media insertion device comprising 
 (a) an envelope feeding station;    (b) a first media insertion station;    (c) a second media insertion station; and    (d) an envelope sealing/receiving station all operatively connected therewith.    
     
     
         31 . An insertion device comprising: 
 (a) an envelope feeding station; and    (b) a media insertion station operatively connected therewith.    
     
     
         32 . A media insertion device comprising: 
 (a) a media transfer assembly;    (b) a feeding chute;    (c) a moving means to position an envelope to receive media with respect to the feeding chute; and    (d) an envelope opening mechanism all operatively connected therewith.    
     
     
         33 . The media insertion device of  claim 32  further comprising a pusher assembly.  
     
     
         34 . The media insertion device of  claim 32 , wherein the media transfer assembly comprises: 
 (a) a vertical support;    (b) a conveying arm;    (c) at least one suction cup affixed in a functional manner to the conveying arm and through which vacuum is selectively applied; and    (d) a hinge connected in a rotatable fashion to both the vertical support and the conveying arm.    
     
     
         34 . The media insertion device of  claim 32 , wherein the feeding chute comprises: 
 (a) a base;    (b) a media rest area at one end of the base; and    (c) a lip at the other end of the base.    
     
     
         35 . The media insertion device of  claim 32  wherein the feeding chute further comprises an air suspension system which provides an air cushion through a plurality of vents in the chute.  
     
     
         36 . The media insertion device of  claim 32  wherein the feeding chute further comprises a recessed groove to facilitate contact between a feeding piston and the media.  
     
     
         37 . The media insertion device of  claim 32  further comprising a feeding piston positioned, timed and coordinated in a manner so as to push media into an open envelope positioned at the lip of the feeding chute.  
     
     
         38 . The media insertion device of  claim 32  wherein the envelope opening mechanism further comprises: 
 (a) at least one elongated stem;  
 (b) a suction cup affixed functionally at the end of the elongated stem;  
 (c) a vertical post to which the opposite end of the elongated stem is mountably fixed; and  
 (d) a carriage means to which one or more of the vertical posts are affixed in a carrying manner so as to permit positioning of the elongated stems.  
 
     
     
         39 . The media insertion device of  claim 32  further comprising an envelope sealing means.  
     
     
         40 . The media insertion device of  claim 32  further comprising one or more error detecting means.