RELATED APPLICATION
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This application is a continuation-in-part of commonly-assigned,
co-pending patent application serial no. 10/712,291, filed November 12, 2003, the
subject matter of which is incorporated by reference herein.
TECHNICAL FIELD
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The present invention relates, generally, to collation and selective
insertion of imaged material, and more particularly, to systems and methods for
dynamic insertion and custom finishing of printed material.
BACKGROUND
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With the advent of computer technology, a wide variety of processing
and handling system are now available to produce customized printed material.
High volume production of selectively inserted printed material and packaging of
the printed material can now be performed by computer-controlled equipment.
Large volume production of advertising materials, account statements, and bulk
mailing can be carried out using high-volume collation and packaging systems. For
example, bulk mailing systems can place several enclosures or inserts into packages
intended for mailing to selected recipients. The packages typically include common
items that are sent to all recipients and additional items inserted into the package for
selected recipients. The creation of mailing packages containing individualized
inserts can only be realized on a cost-effective basis through the use of automated,
high-speed equipment.
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The preparation of individualized packages of printed material requires
the use of scanning technology for product quality control. Typically, selective
insertion systems employ machine readable indicia printed on control documents to
ensure the proper printed materials are enclosed within a designated package. In
one such system, selected inserts are placed into billing statements under the control
of an integrated system controller. The controller directs selective insertion of
enclosures into the billing statements. The system controller directs the inserter to
selectively include inserts with the billing statement according to instructions from
a data processor.
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Selective insertion systems are also used to place inserts into bulk
mailing items, such as advertising mailers and advertising inserts within
newspapers. In one such system, newspapers are collated with materials that vary
depending upon the product interest of selected newspaper subscribers. In addition
to placing selective inserts within the newspaper, the system also prints indicia
identifying the selected subscriber on a jacket of the newspaper.
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High-speed, computer-controlled processing equipment is also used for
permit and pre-sort bulk mailing for delivery to the U.S. Postal Service. Scanning
equipment is used to pre-sort bulk mailings and to inspect and verify that mail
pieces have been properly pre-sorted and proper postage applied. Such systems
include stacking structures for accommodating a plurality of like stationery items.
Printing systems are used to print various parts of information stored by a computer
system on selected stationery items from the stacking structure. Identification
marks are placed on the stationery items for use by the U.S. Postal Service for
marking and identifying pre-sorted letters.
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Automated systems have also been developed that validate the sequence
and package completeness of output from a high-speed printer. The equipment can
add covers and inserts and, if required, bind the printed material together in
a variety of ways and place the printed material in a package. The systems are
configured to assemble a variety of documents, such as insurance policies,
contracts, instructional materials, parts and repair manuals, and business reports of
various types. For example, the system can place particular clauses within
insurance policies that are to be selectively mailed to policy holders residing in
a particular state. The automated printing and assembly equipment thus enables
large volume distribution of insurance policies and other documents that contain
particular information relevant to selected recipients.
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Although computer controlled systems have enabled development of
high-volume printed material handling systems, systems and methods have yet to
be developed to address the particular need for individualized fmished printed
material. Further, advancements in system configuration are necessary to fully
realize the potential of advanced printing and handling systems. Accordingly,
a need existed for systems and methods to address a wide variety of applications
for personalized printed material and finishing of the printed material.
SUMMARY
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In an embodiment of the invention, a method for producing
personalized imaged material includes selectively ejecting predetermined stock
sheets from a plurality of sheet feeders. The stock sheets are sequentially
processed to image personalized information onto the stock sheets to form
personalized sheets and the personalized sheets are sequentially finished.
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In another embodiment of the invention, a method for producing
personalized printed material includes selectively gathering stock sheets and
assembling the stock sheets into designated sets of sheets. The stock sheets in
each designated set of sheets are sequentially processed to image personalized
information onto the stock sheets. The stock sheets are then re-gathered into the
designated sets of sheets and packaged with additional items.
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In yet another embodiment of the invention, a method for producing
personalized printed material includes selectively gathering stock sheets and
assembling the stock sheets into designated sets of sheets. Each stock sheet is
sequentially processed into a feeding system and personalized information is
imaged onto the stock sheets. The stock sheets are re-gathered into the designated
sets of sheets presented for final processing.
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In still another embodiment of the invention, a method for producing
personalized imaged material includes selectively ejecting predetermined stock
sheets from a plurality of sheet feeders to form a sequential order of stock sheets.
Each stock sheet contains specified indicia thereon. The stock sheets are
sequentially processed to image personalized information onto the stock sheets to
form personalized sheets. Each personalized sheet is associated with an additional
item, where a feature of the additional item is related to one or both of the
specified indicia or the personalized information.
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In a further embodiment of the invention, a method for producing
personalized imaged material includes providing a multi-bin collator, where each
bin contains stock sheets having predetermined indicia thereon. Selected bins are
activated in response to control signals from a control system and one or more
stock sheets are fed from the selected bins onto a conveyance device. The stock
sheets are sequentially processed to image personalized information onto the stock
sheets to form personalized sheets and the personalized sheets are sequentially
finished.
BRIEF DESCRIPTION OF THE DRAWING
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FIG. 1a is a front view of an exemplary pre-printed sheet that may be
used as a stock sheet in accordance with the invention;
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FIG. 1b is a front view of the stock sheet illustrated in Fig. 1a having
personalized information printed thereon;
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FIG. 2a is a front view of an insert sheet that may be used as an
addressing vehicle in accordance with the invention;
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FIG. 2b is a front view of the insert sheet illustrated in Fig. 2 having
personalized information printed thereon in accordance with the invention;
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FIG. 3a is a schematic block diagram of a control system arranged in
accordance with the invention;
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FIG. 3b is a schematic block diagram of a general information file
structure in accordance with the invention;
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FIG. 3c is a schematic block diagram of customer data files in
accordance with the invention;
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FIG. 4a is a schematic diagram of two exemplary collation systems
arranged in accordance with the invention;
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FIG. 4b is a schematic diagram of a re-feeder, an imaging system, and
a re-gathering system arranged in accordance with the invention;
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FIG. 4c is a top view of the schematic diagram illustrated in FIG. 4b
and including additional components of a packaging system arranged in
accordance with the invention;
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FIG. 4d is a schematic diagram of an insertion and imaging system
arranged in accordance with the invention;
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FIG. 5 is a flow diagram illustrating a process control sequence for
a single-lane machine in accordance with the invention;
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FIG. 6 illustrates another embodiment of a process control sequence for
a single-lane machine in accordance with the invention;
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FIG. 7 illustrates a process control sequence for a single-lane machine
arranged in accordance with a further embodiment of the invention;
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FIG. 8 is a schematic top view of a dual-lane machine arranged in
accordance with one embodiment of the invention;
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FIG. 9 is a schematic top view of a dual-lane machine arranged in
accordance with another embodiment of the invention;
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FIG. 10 is a flow diagram of a process control sequence for a dual-lane
machine in accordance with the invention;
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FIG. 11 illustrates a process control sequence for a dual-lane machine
in accordance with another embodiment of the invention;
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FIG. 12 is a schematic diagram of a sequential collation and imaging
system arranged in accordance with another embodiment of the invention;
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FIG. 13 is a schematic diagram of a finishing system including a
folding, labeling, and imaging system arranged in accordance with one
embodiment the invention;
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FIG. 14 is a top view illustrating the folding, labeling, and imaging
operation carried out by the finishing system illustrated in FIG. 13;
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FIG. 15 is a schematic diagram of a finishing system arranged in
accordance with one embodiment the invention for associating an object with a
package or with a personalized sheet; and
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FIGs. 16a-16c are top views illustrating a sequential imaging and
finishing process in accordance with an embodiment of the invention.
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It will be appreciated that for simplicity and clarity of illustration,
machine elements shown in the Figures have not necessarily been drawn to scale.
For example, the dimensions of some of the elements are exaggerated relative to
others for clarity. Further, where considered appropriate, reference numerals have
been repeated among the Figures to indicate corresponding elements.
DETAILED DESCRIPTION
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The present invention provides a system and method for low-cost, high-volume
production of personalized printed materials. A computerized processing
system enables a wide range of imaged materials to be automatically processed and
packaged for delivery to recipients. The system and method of the invention can
be utilized to address numerous applications including, but not limited to, direct
marketing, invoice preparation, customized documentation preparation, and the
like. The computer control processing system enables the storage of large
quantities of information concerning various aspects of the recipients of the
personalized imaged materials. The computerized control system also enables
storage of user information that can be selectively coupled with recipient
information to provide personalized imaged materials to selected recipients based
on user criteria and recipient data files.
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As will become apparent from the following description, the various
embodiments of the invention are designed with maximum flexibility to enable the
use of the system for a wide variety of applications and the preparation of small
and large volume imaged material production. Although the exemplary
embodiments of the invention described below generally relate to direct marketing,
those skilled in the art will appreciate that the system and method of the invention
can equally be applied to a wide variety of different imaged materials.
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Shown in FIG. 1a is a front view of a pre-printed sheet 20. In the
illustrative embodiment, pre-printed sheet 20 includes indicia 22 showing the
source of the pre-printed sheet, in this instance Solar Communications, Inc., the
assignee of the present invention and a coupon blank 24. In accordance with the
invention, pre-printed sheet 20 can be one of many such pre-printed sheets having
a variety of coupon blanks and different provider indicia. The provider indicia can
vary in a number of ways including different products, different advertising
information, and different providers, which may be divisions of a single business
entity or different business entities. As used herein, the term "indicia" is intended
to apply to all forms of imaged information including identifying marks, printed
text, graphic elements, and the like.
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FIG. 1b is a front view of pre-printed sheet 20 after processing in the
system of the invention to image personalized information thereon. In accordance
with one aspect of the invention, pre-printed sheet 20 has been subjected to an
imaging process to place customized indicia 26 and 28 on coupon blank 24. As
a result of the imaging process, coupon blank 24 now includes a particular value,
shown as indicia 26, and a barcode, shown as indicia 28, for identification and
tracking purposes. By processing pre-printed sheet 20 through the imaging system
of the invention, a stock sheet has been processed to place personalized
information onto the stock sheet. In accordance with the invention, numerous
additional customized or personalized indicia can be imaged onto pre-printed sheet
20. For example, specific products, additional pricing information, and the like,
could also be imaged on pre-printed sheet 20.
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A front view of an exemplary insert sheet 30 is illustrated in FIG. 2a.
Insert sheet 30 includes provider indicia 32. Insert sheet 30 can be one of a number
of different inserts, including an addressing insert for mailing purposes, a special
insert identifying additional products or services, and the like. In the aspect of the
invention where insert sheet 30 functions as an addressing vehicle, personalized
information in the form of a recipient address 34 is placed on insert sheet 30, as
illustrated in FIG. 2b. Additionally, further provider information 36 can also be
imaged onto insert sheet 30 prior to packaging. Those skilled in the art will
appreciate that numerous additional indicia can also be imaged onto insert sheet 30
including additional provider information, package opening incentives, and the
like.
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A computer control system for preparing personalized printed material
in accordance with the invention is illustrated in FIG. 3a. The control system
includes a data structure 38 that is interfaced to an operations controller 40. Data
structure 38 includes an information database that includes a wide variety of
provider and recipient information. The provider information can include source
identification information, brand information, specific product information, market
pricing, and discount information, and the like. The information database can also
include recipient information, such as identification, product preferences, store
preferences, geographic location, and the like. In another aspect of the invention,
information database 42 can include information relating to additional applications
of the invention, such as invoicing, custom document preparation, preparation of
personalized books, and the like. Where the provider is, for example, a service
company, such as a utility company, the provider information can include regional
rate information, billing code information, invoice routing information, and the
like. The recipient information could include annual usage information, special
fees or rate information, rate discount information, and the like. Further, where the
provider is a book publisher or distributor, the recipient information could include,
for example, names for insertion into personalized books, such as, for example,
children's books, and the like.
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In accordance with the invention, the assembled information in
information database 42 is organized into general information files 44 and specific
information files 46. FIG. 3b illustrates an example of the file organization within
general information files 42. The file database includes user profile data 48 and
various topic category files 50. The content of user profile data 48 will depend
upon the particular business activity of the user, in addition to the number and type
of user locations, the particular products or services offered by the user, and the
like. Topic category 50 can include particular product information, such as product
type, product brand, general pricing information, such as discounts, and the like.
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Specific information files 46 can include numerous data relating to
specific recipients of the personalized printed materials. As illustrated in FIG. 3c,
the recipient data files can include identification information, specific pricing
applying to a specified recipient or groups of recipients, product preferences for
individual recipients and groups of recipients, store preferences of individual
recipients, geographic location of particular recipients, and the like.
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Those skilled in the art will appreciate that the architecture of data
structure 38 described above is but one of many different possible architectures of
a data structure for the present invention. Depending upon the particular
application of the present invention, data structure 38 can have additional
information files from those described above. For example, additional information
files can include regulatory information, statutory information, and the like. In
accordance with the invention, as illustrated in FIG. 3a, operations controller 40 is
interfaced with a variety of processing systems used in the production of
personalized imaged material.
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Operations controller 40 provides command and control instructions to
one or more collators 52, refeeders 54, imaging systems 56, inserters 58, and
finishing systems 60. Operations controller 40 responds to commands to provide
personalized printed materials intended for particular recipients as requested by
specific users.
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A system manager 62 responds to input instructions from operations
personnel and instructs operations controller 40 to prepare sets of personalized
printed material using particular data files maintained in data structure 38. System
manager 62 initiates and maintains all of the data files within data structure 38 and,
accordingly, maintains an awareness of the status of all data files in data structure
38.
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Those skilled in the art will appreciate that the functions of system
manager 62 and operations controller 40 can be carried out by electronic devices,
such as microprocessors, microcontrollers, and the like. Further, the databases
maintained in data structure 38 can be stored in hard memory devices, such as
dynamic-random-access-memory (DRAM), static-random-access-memory
(SRAM), on-board memory structures, and the like. System operators can enter
command instructions to system manager 62 and data into data structure 38
through any of a number of different input/out devices, such as computer terminals,
voice-activated systems, scanning devices, and the like.
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Upon receiving instructions in the form of a job request from system
manager 62, operations controller 40 matches the job request information with user
profile data 48 and topic category files 50 with one or more recipient data files in
specific information files 46. Once the user information and recipient information
is matched, operations controller 40 relays command signals to the various
operating equipment to produce the requested personalized printed material.
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FIGs. 4a-4d illustrate one embodiment of a single-lane machine for
practicing the present invention. The various components making up the single-lane
machine include a collator 70, a re-feeder 72, an imaging system 74, a re-gathering
system 76, and a finishing system 78. The single-lane machine can also
include an insertion system 80 and a second imaging system 82.
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In accordance with the invention, collator 70 can be one of several
different types of collators. Two exemplary collators are schematically illustrated
in FIG. 4a. A vacuum and rotary feed collator 84 includes a bin 86 that gravity
feeds stock sheets 88 to a rotary feed device 90. Rotary feed device 90 in
conjunction with a belt 92 sequentially feeds stock sheets 88 onto the spaces
between conveyor lugs 94. Conveyor lugs 94 are distributed along conveyor
system 96. As conveyor system 96 moves in a lateral direction from left to right,
rotary feed device 84 feeds stock sheets 88 onto the space between conveyor lugs
94 in response to commands received from operations controller 40 through
a system relay 98. System relay 98 activates rotary feed device 84 in response to
instructions from operations controller 40 and returns operational status
information to operations controller 40.
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In accordance with one embodiment of the invention, a number of rotary
feed systems 84 are positioned above and laterally distributed along conveyor
system 96. Each of the rotary feed systems supplies a stock sheet from its bin onto
select spaces on conveyor system 96. After a select space has passed beneath
several rotary feed systems 84, a designated set of sheets 100 is assembled on
a select space of conveyor system 96. The make-up of designated set 100 depends
upon the particular activation sequence of rotary feed system 84 as conveyor
system 96 moves in a generally left to right direction. Those skilled in the art will
recognize that rotary feed systems 84 could also be positioned along side of
conveyor system 96 and feed stock sheets either at a right angle to the direction of
motion of conveyor system 96 or in the same direction of motion. As described
above, operations controller 40 responds to commands from operations personnel
and uses information in data structure 38 to initiate activation signals to the various
rotary feed systems of the collator.
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A friction feed collator 102 is also illustrated in FIG. 4a. Friction feed
collator 102 includes a bin 104 containing stock sheets 88. A friction belt 106
grabs stock sheets that are released from bin 104 and feeds the stock sheets through
a feed conveyor system 108 onto the spaces between conveyor lugs 94. In
similarity to rotary feed collator 84, friction feed collator 102 includes a number of
friction feed systems positioned above and laterally distributed along conveyor
system 96. Each friction feed system is equipped with a system relay 110 that
receives instructions from operations controller 40 and sends operation status
information back to operations controller 40. Those skilled in the art will
recognize that friction feed systems could also be positioned along side of
conveyor system 96 and feed stock sheets either at a right angle to the direction of
motion of conveyor system 96 or in the same direction of motion.
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Collator 70 can deliver a varying number of stock sheets into the space
between lugs 94 on conveyer system 96. In this method, the feed device delivers
multiple copies of the stock sheets in its bin into the same space on conveyor
system 96. Accordingly, a designated set of sheets at a specific location on
conveyer system 96 can have a number of sheets from the same bin. Collator 70
can also delivery multiple sheets from more than one bin into the same space on
conveyor system 96. Thus, the make up of a designated set of sheets can also
include multiple sheets from several bins. The ability to feed multiple sheets from
the same bin is advantageous, for example, in the case where a designated set of
sheets include admission tickets to an event, such as a sporting event, or fine arts
event, or the like.
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Conveyor system 96 transfers designated set 100 to a pick-up system
112. As illustrated in FIG. 4b, pick-up system 112 is a component of re-feeder 72.
Re-feeder 72 also includes a bin 114 and friction feed belt 116. Designated sets
100 are loaded into bin 114 and individual stock sheets are sequentially fed by
friction feed belt 116 through transfer system 118 and into aligning system 120.
Re-feeder 72 sequentially feeds stock sheets into aligning system 120 upon
commands received through a system relay 122 from operations controller 40.
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In accordance with one embodiment of the invention, re-feeder 72 is
configured to operate at transfer rates substantially greater than the operational rate
of collator 70. In a preferred embodiment of the invention, re-feeder 72 operates at
a rate that ranges from about the same rate as collator 70 (about a 1 to 1 operating
speed ratio) to about 2 to about 50 times faster than collator 70. The high operating
speed of re-feeder 72 ensures that designated sets 100 transferred from collator 70
can be sequentially processed at a rate that will accommodate the large number of
stock sheets 88 contained within each designated set 100.
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Those skilled in the art will recognize that other types of feeding
systems can be used to assemble the designated sets of sheets prior to imaging. For
example, a continuous rotary feed system can be used to collect the sets of sheets
from the collator and sequentially deliver the individual sheets to aligning system
120. Further, an operator can manually collect the sets of sheets and deliver the
sets of sheets to aligning system 120. Accordingly, the present invention
contemplates human intervention where necessary or where cost effective to
provide interfacing between operating systems.
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Regardless of the method used to collect the designated sets of sheets,
aligning system 120 aligns each stock sheet 88 to position each stock sheet at
a proper orientation for imaging by imaging system 74. Once aligned by alignment
system 120, stock sheets 88 are transferred to a vacuum belt 124 in imaging system
74. As each stock sheet 88 is transferred to vacuum belt 124, a scanning device
126 scans the stock sheet for a code or other graphic indicia to ensure that the
correct stock sheet will be presented to imaging system 74. Scanning device 126
sends optical signals to a digital signal converter 128 that relays scan information
to operations controller 40. Operations controller 40 verifies that the stock sheet
88 is a proper member of designated set 100 prior to imaging personalized indicia
onto stock sheet 88 by imaging system 74. If scanning device 126 detects an
incorrect sheet, imaging system 74 diverts the entire set of sheets from which the
incorrect sheet originated to a waste bin (not shown) and operations controller 40
reorders the set of sheets containing the incorrect sheet.
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While the foregoing processing sequence envisions that all of the stock
sheets will be imaged with personalized information, the present invention also
contemplates processes in which not all of the sheets in a set of sheets are imaged.
In some cases it may not be desirable to image personalized information on each
sheet within a set of sheets. For example, cover and end sheets within a set may
have a different format than the remaining sheets within a set. Accordingly, it is
within the scope of the present invention that certain ones of designated set 100 are
transferred through imaging system 74 without being imaged.
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In accordance with the inventive process, vacuum belt 124 positions
stock sheet 88 within the imaging field of an imaging device 130. Imaging device
130 can be one of a number of different imaging devices including a variable data
imaging system, a laser printer, an ink jet printer, and the like. In a preferred
embodiment of the invention, imaging device 130 is a solvent-based ink jet system
that can image stock sheets at a conveyor speed of about 500 to about 1000 linear
feet per minute. Imaging system 130 is preferably a system configured to image
stock sheets 88 from a position immediately above the stock sheets. Alternatively,
imaging system 130 can also image stock sheets 88 from a position immediately
below the stock sheets. In accordance with the invention, imaging device 130 also
includes an imaging control system 131 and vacuum system 132 that provides
vacuum pressure for vacuum belt 124.
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Preferably, re-feeder 72 and imaging system 74 operate at a speed that is
consistent with the demand for individually processing the stock sheets within
a designated set 100 that contains a maximum number of stock sheets. At such an
operating speed, the number of stock sheets in each designated set can vary, while
the linear speed of vacuum belt 124 remains constant. For example, where
a designated set 100 contains three stock sheets and another designated set 100
contains seven stock sheets, operations controller 40 will instruct re-feeder 72 to
skip four feeds, plus a number for buffer purposes when processing the three-sheet
designated set. Operations controller 40 also instructs refeeder 72 to skip a certain
number for buffer purposes when processing the designated set containing seven
stock sheets. The insertion of buffers when processing designated sets 100 having
different numbers of stock sheets allows time, if needed, for the re-gathering of the
designated sets and transferring the designated sets to final processing. The
number of buffer positions depends on the overall operating speed of the single-lane
machine.
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Those skilled in the art will recognize that a wide variety of
personalized indicia can be imaged onto the stock sheets by imaging system 74.
The type of information can vary depending upon the nature of the material being
imaged. For example, in the case of invoice preparation, the personalized
information can include usage of services, such as utility services including,
electricity, water, and the like, and for communications services, such as television,
telephone, internet services, and the like. In addition to advertising mailers, the as
described above the stock sheets can include admission tickets to various events.
In this case, there can be multiple tickets for a given event date and imaging system
74 can image each ticket for a given date with seat number, ticket price, and the
like. Accordingly, it is within the scope of the present invention that all such
printed materials be processed by the system and method of the invention.
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After stock sheets 88 are imaged to contain personalized information,
they are transferred to re-gathering system 76 and reassembled into the original
designated sets initially prepared by collator 70. Where needed for final processing
purposes, re-gathering system 76 can include a rotary indexing device 134 that
delivers re-gathered designated sets 100 to a conveyor 136. Stations 138 within
rotary indexing device 134 rotate into alignment with vacuum belt 124 and receive
personalized sheets 89 from imaging system 74. Alternatively, another type of
indexing and turn over device, such as a belt system and the like can also be used.
In yet another alternative, re-gathering system does not include a turn over device.
Those skilled in the art will appreciate that the re-gathering system illustrated in
FIGs. 4b-4d is one of many different possible equipment configurations for re-gathering
the sheets processed by imaging system 74.
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In an alternative embodiment, collator 70, re-feeder 72, imaging system
74, and re-gathering system 76 can all operate at variable transfer rates. These
systems can be independently controlled by, for example, servo motors that are
electronically linked to operations controller 40. Operations controller 40 monitors
the numbers of sheets in the sets and the operating speed of each operating system.
By varying the operating speeds through an interlinked control system, a relatively
constant throughput can be obtained where the number of sheets in consecutive
sets varies. In synchronizing the operating speeds, one system can be instructed to
operate at a higher transfer rate than an adjacent system, and visa versa. The use of
electronically-linked, machine speed controls can be broadly employed to
synchronize the collator operating speed and the various interface components and
processing components in the finishing operations. Accordingly, an interlinked
operating speed control system that independently varies the transfer rates of the
various process systems is contemplated by the present invention.
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Once re-gathered and indexed, the designated sets of personalized sheets
101 can be transferred to a number of fmishing operations. Those skilled in the art
will appreciate that numerous types of finishing procedures can be carried out to
organize the designated sets of sheets into a user specified format. For example,
the designated sets of sheets can be bound together or attached using some other
physical attachment means, such as clips, pins, staples, glue, and the like. Also the
designated sets of sheets can be packaged by overwrapping, or shrink wrapping, or
the like. Additionally, the designated sets of sheets can be inserted into an
envelope suitable for mailing with the U.S. Postal Service or another document
delivery service. In the machine embodiment illustrated in Figs. 4a-4d, the single-lane
machine is arranged to insert index sets of sheets 101 into envelopes 140.
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As described above, the single-lane machine can also include insertion
system 80 and second imaging system 82. Insertion system 80 includes a bin 142
that contains insert sheets 144. Insert sheets 144 can be any of a number of
different types of sheets having a variety of information imaged thereon. In the
embodiment of the invention described with reference to FIGs. 1 and 2, insert
sheets 144 are intended to provide address information for particular recipients in
addition to user information.
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Upon receiving control signals from operations controller 40, system
relay 146 commands insertion system 80 to transfer an insert sheet 144 from bin
142 through transport system 148 to second imaging system 82. Second imaging
system 82 includes an imaging device 150 that receives image control commands
from operations controller 40 through imaging control system 152. Second
imaging system 82 also includes an alignment system 154 to properly align insert
sheets 144 within the imaging field of imaging device 150. In similarity with
imaging device 130, imaging device 150 can be a variable field imaging system, or
printing system, such as a laser printer or an inkjet printer, or the like. In
a preferred embodiment of the invention, imaging device 150 is an inkjet printing
system.
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Once personalized information has been imaged onto insert sheet 144,
the second imaging system 82 transfers the insert sheet to a selected station within
rotary indexing 134. As a result of the operation of insertion system 80 and second
imaging system 82, designated sets of sheets 101 each contain an insert providing
address information to selected recipients.
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Although the single-lane machine described above has been set forth
with respect to particular machine components, those skilled in the art will
appreciate that numerous different mechanisms exist for performing the various
operations described above. For example, in addition to rotary indexing systems,
other types of vertical stacking indexing systems and lateral stacking indexing
systems could also be used. Further, in addition to the rotary feed and friction feed
collators described above, a swing arm collator could also be used to prepare
designated sets of sheets for delivery to the re-feeding system. Further, the single-lane
machine described above can include additional sensing devices and
electronic control and relay systems to send information to the operations
controller and to receive instructions from the operations controller. Additionally,
although the single-lane machine described above has been illustrated with
reference to conveyor belt systems for transferring the stock sheets and designated
sets of sheets, other types of conveyance mechanisms can also be used. For
example, rollers, air bearing systems, vibrating systems, and the like.
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Although the machine described and illustrated above sets forth an
embodiment in which all machine components are linked together, those skilled in
the art will appreciate that the system can be assembled as individual components.
For example, a human operator or a mechanical transfer system can provide an
interface between the various machine components. In an alternative embodiment,
the collator can feed sets of sheets to a collection area and a human operator or a
mechanical transfer system can deliver the sets of sheets to the re-feeder. Further,
the sets of documents from the re-gathering system can be transported to the
finishing system by a human operator or a mechanical transfer system.
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Those skilled in the art will appreciate that the machine system
described above can be operated under a number of different control programs.
The following description sets forth several different program control sequences
that can be used for the machine system described above. In accordance with the
invention, the following program control sequences can also be employed to
operate machine systems that differ from those described above.
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One embodiment of a process control sequence for a single-lane
machine arranged in accordance with the invention is illustrated in FIG. 5. The
control sequence begins by reading database information from data structure 38
into operations controller 40 at step 160. Re-feeder 72 is programmed for
a maximum number of inserts at step 162. The various bins of collator 70 are
activated by commands from operations controller 40 at step 164. Information
regarding the number of inserts or stock sheets to be included in a designated set is
relayed to re-feeder 72 at step 166. Scanning device 126 is instructed to scan each
sheet for verification at step 168. Imaging control system 131 upon receiving
instructions from operations controller 40 prints personalized information on the
sheet at step 180. At step 182 an optional drying procedure is carried out cure the
imaged sheet. The optional drying system can reside in proximity to vacuum belt
124 at a position downstream from imaging device 130. Re-gathering system 76 is
instructed to index, collect and re-collate the printed sheets into the original sets of
sheets at step 184. If needed, the re-collated sets of sheets can be turned over or
otherwise positioned for final processing at step 186. Final processing as described
above is carried out at step 188.
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An additional embodiment of a process control sequence for the single-lane
machine described above is illustrated in FIG. 6. The processing sequence
illustrated in FIG. 6 is intended for use with a variable speed re-gathering system.
The process sequence is similar to that illustrated in FIG. 5 with the exception that
the re-feeder is not programmed for a maximum number of inserts. Steps 190 and
192 are similar to steps 160 and 164 in the process sequence described above. At
step 194, operations controller 40 sends instructions to re-feeder 72 for the required
number of sheets for each designated set. Steps 196, 198, and 200 are similar to
steps 168, 180, and 182 described above. At step 202, the number of stock sheets
in each designated set is relayed by operations controller 40 to re-gathering system
76. Electronic control within re-gathering system 76 adjusts the speed of rotary
indexing system 134 according to the number of sheets required in each set. Steps
204 and 206 are similar to steps 186 and 188 described above.
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FIG. 7 illustrates a process control sequence for the single-lane machine
described above in the embodiment in which the single-lane machine includes an
insertion system 80 and second imaging system 82. Steps 208-224 are similar to
steps 160-186 described above. At step 226, operations controller 40 instructs
insertion system 80 and second imaging system 82 to provide a personalized insert
sheet into the designated sets of sheets. At step 228, the insert sheet is dried in an
optional drying system that can be located immediately downstream from second
imaging system 82. Step 230 is similar to step 188 described above.
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In accordance with the invention, an alternative embodiment of a system
for producing personalized printed material is illustrated in FIG. 8. The system
includes a first collator 232 coupled to a first re-feeder 234. A second collator 236
is coupled to a second re-feeder 238. In accordance with the invention, first
collator 232 includes more bins then second collator 236. A first imaging system
240 is coupled to first re-feeder 234 and a second imaging system 242 is coupled to
second re-feeder 238. The first imaging system 240 and the second imaging
system 242 transfer sheets with personalized information imaged thereon to
a reassembly station 244. Reassembly station 244 includes a merging station 246
where sets of sheets originating from first collator 232 and imaged with
personalized information by imaging system 240 and sheets originating from
second collator 236 and image with personalized information by second imaging
system 242 are merged together. Merging station 246 transfers the merged sets of
sheets to a final processing system 248. Final processing system 248 can include
a turnover device 250 and, in one embodiment of the invention, a packaging
system 252 that packages the sets of sheets in one of the packaging types described
above. The packaging system is coupled to a transport system 254 that transports
the packaged sets of sheets to a staging area for storage or delivery.
-
In accordance with the embodiment of the invention illustrated in
FIG. 8, second collator 236 is loaded with stock sheets that are intended for
insertion into the set of sheets to identify special matters to be included within the
designated sets of sheets. For example, the stock sheet loaded in second collator
236 can be generic sheets that are intended to be inserted within all designated sets
of sheets that are produced under one or more job requests.
-
In accordance with the invention, yet another alternative embodiment of
a system for producing personalized printed material is illustrated in FIG. 9. In
similarity with the embodiment illustrated in FIG. 8, the system includes a first
collator 232, a first re-feeder 234, and a first imaging system 240. Also included
are a second collator 236, a second re-feeder 238, and a second imaging system
242. In the system illustrated in FIG. 9, merging station 246 is positioned in line
with first collator 232. Reassembly station 244 transfer sets of sheets from second
imaging system 242 to merging station 246. Final processing station 248 is also
aligned with first collator 232. Those skilled in the art will recognize that other
arrangements are possible for the dual-lane illustrated in FIG. 8. For example, in
accordance with the invention, additional collators could be added and coupled to
reassembly station 244 and their output merged at merging station 246.
-
FIG. 10 illustrates a process control sequence for a dual-lane machine as
illustrated in Figs. 8 and 9. At step 260, operations controller 40 receives
instructions from a system operator to assembly sets of personalized sheets
according to a user job request. At step 262, first and second re-feeders 234 and
238 are programmed to assemble a maximum number of inserts or stock sheets into
each designated set. Each of collators 232 and 236 are then directed according to
processing command sequences 264 and 266, respectively. Each of the individual
processing steps within command sequences 264 and 266 are similar to the steps
previously described. At step 268, operations controller 40 instructs merging
station 246 to re-gather the sheets from imaging systems 240 and 242. The merged
sets of sheets are then turned over, if necessary, by a turnover system 250 at step
270. Final processing as previously described is then carried out a step 272.
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A process control sequence for a dual-lane machine in accordance with
another embodiment of the invention is illustrated in FIG. 11. The processing
sequence illustrated in FIG. 11 provides operating instructions for a dual-lane
machine as illustrated in Figs. 8 or 9. The system, however, also includes
an insertion system and imaging system as illustrated in FIG. 4d. Steps 274 and
278 are the same as steps 260 and 262 described above. Also, processing control
sequences 280 and 282 are the same as processing control sequences 264 and 266.
Steps 284 and 286 are the same as steps 268 and 270. At step 288 operations
controller 40 instructs the insertion system and the imaging system to provide
a personalized sheet for each set of sheets that can be used, for example, for
addressing purposes. An optional drying step for the insert sheets is performed at
step 290 and final processing is carried out at step 292.
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In an alternative embodiment of the invention, stock sheets are
individually fed directly from a collator and sequentially imaged. The alternative
embodiment differs from the embodiment described above in that the stock sheets
are not gathered into sets of sheets nor processed by a re-feeder prior to imaging.
Rather than gather the sheets into sets, the sheets are sequentially fed one at a time
to the imaging system directly from a collator. In the alternative embodiment, the
sheets can be gathered after imaging and before final processing.
-
The method in accordance with the alternative embodiment further
includes sequentially finishing the imaged sheets. In the finishing process, the
sheets are processed one at a time. The finishing process can include simply
folding the imaged sheets. Also, the finishing process can include placing
personalized indicia on either an inner surface of the sheets or an outer surface of
the folded sheets, or on both the inner surface and the outer surface. Alternatively,
the finishing process can also include packaging the imaged sheets with selectively
gathered sheets into a package. Additionally, one or more additional items can be
associated with the package. For example, an object such as a promotional item
can be associated with package. The sequential processing is controlled by the
control system described above.
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Illustrated in FIG. 12 is a schematic diagram of a sequential collation
and imaging system arranged in accordance with the alternative embodiment of the
invention. A sequential collator 300 is coupled to an aligning system 302, which is
in turn coupled to an imaging system 304. In similarity to collator 102, collator
300 includes a series of bins 306 that hold stock sheets 308. Each bin includes
sheet feeding apparatus for delivering stock sheets to a conveyor system 310. In
contrast to the operation of the collator illustrated in FIG. 4a, collator 300
sequentially ejects sheets from the sheet feeders onto conveyer system 310 for
delivery one at a time to alignment system 302.
-
Alignment system 302 aligns each sequentially feed sheet and delivers
each sheet by means of a conveyor system 312 to imaging system 304. Imaging
system 304 is similar to imaging system 74 and includes an imaging device 314
and an optional scanning device 316. In accordance with the previous embodiment
described above, personalized indicia is imaged onto the sheets by transferring the
sheets past imaging system 314 on a conveyor system 318 to produce personalized
sheets 320. Scanning device 316 communicates with the control system and
verifies that the correct sheet is about to be imaged. After imaging, personalized
sheets 320 are transferred by conveyor system 318 a finishing system, where
personalized sheets 320 are sequentially processed into a final form.
-
As described above, the present invention also contemplates processes
in which not all of the sheets are imaged. In some cases it may not be desirable to
image personalized information on each sheet. Accordingly, it is within the scope
of the present invention that certain ones of stock sheet 308 are transferred through
imaging system 304 without being imaged.
-
The finishing system coupled to imaging system 304 can be similar to
finishing system 78 described above, with the exception that the sheets are entirely
sequentially processed to their final form. One embodiment of a finishing system
is illustrated in FIG. 13. The finishing system includes a folding system 322, a
labeling system 324, and an imaging system 326.
-
Folding system 322 can be any of a number of different sheet handling
systems that manipulate flat sheets into a folded form. In the embodiment
illustrated in FIG. 13, folding system 322 is a plow fold that receives personalized
sheets 320 from conveyor system 318 and folds the sheets in a bifold by forcing
one half of each sheet over on itself producing folded sheets 334. Personalized
sheets 320 are propelled through folding system 322 by a conveyor 328.
-
A top view illustrating the folding, sealing, and imaging operation is
illustrated in FIG. 14. Each sheet is folded along a folding line 336. In one
embodiment of the invention, folding line 336 is a perforated line formed on or
near a center line in the stock sheets.
-
Once the personalized sheets are folded, labeling system 324 forms a
wafer seal 330 to secure the fold. In the illustrated embodiment, labeling system
324 is a labeling device that applies wafer seal 330 to the outside edge of the
folded sheets opposite from folding line 336.
-
Following seal formation, imaging system 326 images personal
information 332 on an outer surface of folded sheets 334. Imaging system 326 is
similar to the imaging systems described above. Information 332 can be a variety
of personalized information, such as specialized advertising, discount offers,
recipient address information, and the like. Where personalized indicia is to be
placed on an inner surface of personalized sheets 320, an additional imaging
system (not shown) is employed to place the indicia on the sheets prior to
processing the sheets though folding system 322.
-
Although the foregoing finishing process is described in the context of a
fully automated process, those skilled in the art will recognize that manual
handling operations can be performed at various stages of the process. For
example, operators can be used to collect stacks of sheets from the previous
operation and transfer the sheets to the next operation. As the sheets are imaged by
imaging system 304, an operator can collect the sheets and place the sheets in
transfer bins. The sheets can then be taken by the operator to a folding system and
be sequentially processed from the bins through folding system. Accordingly, the
present invention contemplates human intervention to assist processing operations,
for example, where machine cost is prohibitive or where mechanical interfacing is
impractical.
-
Those skilled in the art will recognize that the finishing operation
illustrated in FIGs. 13 and 14 is one of many different kinds of finishing operations
that can be carried out with the personalized sheets prepared in accordance with the
invention. For example, various types of packaging operations can also be
performed. In one embodiment of the invention, personalized sheets prepared by
any of the foregoing methods are placed in a package. The package can be an
envelope, such as envelope 140 or a plastic package, or the like.
-
As part of the finishing process, the personalized sheets can be packaged
with one or more additional items. For example, an object can be attached to the
package or inserted into the package with the personalized sheet or sheets. Further,
the object can be attached directly to the personalized sheets. The objects can
include, for example, product samples, vouchers, marketing aids, such as games,
and the like.
-
A schematic diagram of a system and method for associating an item
with the personalized sheets according to one embodiment of the invention is
illustrated in FIG. 15. A package attaching system 340 includes first and second
package delivery systems 342 and 344, respectively. Each of package delivery
systems 342 and 344 includes a feed station 346 and a rotary placement device
348. A conveyor system 350 transports personalized sheets 320 past the package
delivery systems. A number of objects to be attached to personalized sheets 320
are loaded into feed stations 346.
-
In accordance with an embodiment of the invention, package attaching
system 342 can deliver more than one type of object can be attached to the
personalized sheets. For example, package delivery system 342 can provide a
product sample 352 for attachment to designated personalized sheets 354, while
package delivery system 344 provides vouchers 356 for attachment to designated
personalized sheets 358. In a process where objects are attached to the
personalized sheets, a gluing system 359 applies glue at a designated location on
the upper surface of personalized sheets 230 as the sheets are received from the
preceding operation and transported by conveyor system 350.
-
In addition to objects such as product sample, marketing aids, vouchers,
and the like, additional personalized sheets can be associated with personalized
sheets 374. For example, coupons previously processed to image personalized
information for a particular recipient can be inserted into a package and the
package attached to personalized sheets 374. Further, instead of attaching an item
to personalized sheets 320, the items can be inserted into a package by a package
insertion system, or over wrapped or shrink wrapped as described above.
-
Although only two package delivery systems are illustrated in FIG. 15,
those skilled in the art will recognize that numerous such package delivery systems
can be employed for delivery of a variety of objects for attachment or package
insertion. Further, the package delivery systems can be employed to attach two
different objects to the same sheet or insert two different objects into the same
package. In a process where objects are attached to personalized sheets 320,
package attaching system 340 can be coupled to folding system 322 to prepare
folded sheets 334 that include an object attached inside the folded sheet.
-
A process for sequentially imaging and finishing personalized sheets is
illustrated in FIGs. 16a-16c. In accordance with the process described above, a
collator, such as collator 300 sequentially places stock sheets 360 into spaces 362
between lugs 364 on a conveying device 366. Each stock sheet 360 includes
previously placed indicia 368 thereon. A control system, such as the control
system illustrated in FIGs. 3a-3c, directs collator 300 to eject a particular stock
sheet 360 onto a particular one of spaces 362 on conveying device 366. Under the
direction of the control system, stock sheets 360 are arranged in a pre-designated,
sequential order on conveying device 366. As illustrated in FIG. 16a, each stock
sheet contains different indicia 368 thereon.
-
An alignment system, such as alignment system 302, aligns the stock
sheets on a vacuum belt 370 and a scanning device, such as scanning device 316,
communicates with the control system and verifies that the scanned stock sheet is
the correct stock sheet for its occupied position in the sequence. An imaging
system, such as imaging system 304, images personalized information 372 onto
each stock sheet to produce personalized sheets 374. As described above, the
present invention also contemplates processes in which not all of the sheets are
imaged with personalized information.
-
Once personalized sheets 374 are imaged, objects are attached to the
personalized sheets, as illustrated in FIG. 16b. Gluing system 359 applies glue 376
to one or more predetermined locations on personalized sheets 374. Glue 376 is
positioned above folding line 336 so that objects can be attached generally opposite
to personalized information 372.
-
In accordance the illustrated embodiment of the invention, different
objects can be attached to personalized sheets 374 depending upon the content of
indicia 368 and the content of personalized information 372. For example, object
378 is attached to personalized sheet 380, while object 382 is attached to
personalized sheet 384. In this way, a particular recipient can receive a mailing,
for example, that contains a personalized advertising sheet having a store logo, a
personal message directed to the particular recipient, and an item, such as a product
sample, that is related to a particular retailer or to product information in the
personal message.
-
Once objects are attached, personalized sheets 374 are folded using a
folding device, such as folding system 322, and sealed using a labeling device,
such as labeling system 324, to place wafer seals 330 on folded sheets 386. An
imaging system, such as imaging system 304, is used to place information 388,
such as name and address information, and the like, on the outer surface of folded
sheets 386.
-
Those skilled in the art will recognize that the order of the process
steps described above can be varied to carry out a number of different finishing
processes. For example, instead of attaching an object and folding the personalized
sheet over the object, the object can be attached to an outside surface of the folded
sheets.
-
Thus is apparent that there has been described a system and method
for producing personalized imaged material that fully provides the advantages set
forth above. Those skilled in the art will recognize that numerous modifications
and variations can be made without departing from the spirit of the invention. For
example, the collators and insertion systems can be configured in a variety of
layout formats to accommodate varying floor space requirements. Accordingly, all
such variations and modifications are within the scope of the appended claims and
equivalents thereof.
