WO1992000879A1

WO1992000879A1 - A system for producing an individualized packet

Info

Publication number: WO1992000879A1
Application number: PCT/US1990/007458
Authority: WO
Inventors: Robert E. Katz; John H. Jones; George P. Hipko; Stanford B. Silverschotz; James Hoffman; Michael Dennis; William F. Pearson; Kenneth Wurtzel; Jack Rosenbloom
Original assignee: Webcraft Technologies, Inc.
Priority date: 1990-07-09
Filing date: 1990-12-19
Publication date: 1992-01-23
Also published as: EP0537149A4; AU7212691A; EP0537149A1

Abstract

A system for producing an individualized multiple piece solicitation packet (P) is disclosed wherein the packet is produced on an in-line basis by use of specialized feed (40), conveyor (42), control (43), marking (44) and packaging assemblies (48) wherein all of the selected insert sheets (51) are uniquely-marked to identify the particular recipient.

Description

A SYSTEM FOR PRODUCING AN INDI IDUALIZED PACKET

Field of Invention

This invention relates to a mass distributable packet which is individualized for a given recipient both as to included inserts and marking for a particular addressee, and the in-line system used to produce such packets.

This is a continuation-in-part application of an application Serial Number 07/360,040, filed June 1, 1989, and United States Patent Application Serial Number 07/430,869, filed October 31, 1989.

Background of the Invention

Large scale distribution of multiple advertising pieces and coupons by either mail or newspaper has become a major advertising practice.

The large volume distribution, although producing a good return, is very costly. To increase effectiveness of this type of advertising, individualized packets, containing the name and addressee has been used. -a-

To further increase effectiveness and reduce unit cost, combining multiple coupons or insert pieces for different products and specifically directed to a particular individual or group of individual, is contemplated.

Such mass distributions involving unusually large numbers of individuals to whom a particular advertising packet is directed is difficult to produce on a reasonable cost basis since each item of the insert is to be particularly selected for a given individual, and will be different from the items produced for other individuals as part of that distribution advertising effort, allowing the advertiser to target future coupons to those who responded to prior offerings. The cost and time involved in attempting to produce such a packet on a manual sort basis, would be prohibitive. However with the assembling and production of such a packet on an automated mechanical assembly, it would be possible to produce such packets at a substantially lower unit cost.

Another disadvantage of mass advertising and coupon distribution packets is the inability to determine which individuals responded to the advertising efforts. The marking of each individual coupon with a code specifically identifying the addressee which is machine readable, has become very helpful to the advertiser. Individuals who did not respond to the advertising can be eliminated from lists to be used in the future, thus reducing substantially the number of pieces required. Alternatively, the value of coupons can be adjusted in subsequent mailings to entice use, by consumers. Conversely through market responses the advertiser can target market coupons to nonusers of specific products. Consequently such a capability can be a large factor in reducing the cost of the advertising effort.

Summary of the Invention

Accordingly, this invention is directed to the producing of a multiple piece solicitation packet which is individualized with respect to both the content and the marking of the insert pieces making up the packet.

The packet is produced on an in-line basis by use of specialized feed, conveyor, control, marking, and packaging assemblies which make it possible to produce individualized and personalized packets on a large volume basis.

The insert pieces of each packet are selected for the particular addressee to receive it, and all insert sheets are uniquely-marked to identify the particular recipient.

The feeder assemblies are compact and, large numbers of them, 150 units or more can be arranged serially to give a wide selection of insert or coupon pieces as few as one (1) but, usually 16 to 44 to a packet, for a given addressee. Further, the feeder assemblies are able to feed coupons on command at a very rapid rate, and to accurately place the coupons on a fast moving conveyor assembly.

The conveyor assembly holds a number of individual groups of coupons or sheets simultaneously at spaced intervals. The individual sheets of each group are accurately held in a fixed shingled position on the conveyor with a small transverse end section of each sheet or coupon exposed to a marking assembly.

The marking assembly places an identical marking on all the pieces of each group which is distinctive and identifies that particular group with the individual to receive the packet. The operation of the conveyor and selective feeder assemblies interact and operate in response to a control assembly which operates on the basis of presupplied data on the addressees and the coupons or insert pieces would be designated for such individual.

In-line packaging means having simultaneously addressed or pre-addressed wrapper sections makes it possible to group and package individualized coupon or insert groups on an automated, rapid basis.

Description of the Drawings

Figure 1 is a perspective view of a group of inserts enclosed within an envelope to form a packet.

Figure 2 is a section along to 2-2 of Figure 1.

Figure 3 is a perspective view of the address side of the packet of Figure 1.

Figure 4 is a perspective view of a packet with a plastic film outer wrap.

Figure 5 is a cut-away view of the packet of Figure 4 illustrating the tear open section.

Figure 6 is a block diagram of the system for producing the packet of Figures 1 and 4. Figure 7 is a perspective view showing the marking of an insert group.

Figure 8 is a schematic view of the insert group gathering assembly.

Figure 9 is a perspective more detailed schematic view of the insert packet producing system.

Figure 10 is a diagrammatic view of the insert supply magazine and the feed assembly as showing their positioned with respect to the conveyor.

Figure 11 is a perspective view of the set of container and coupon or insert ribbons supplied to each feed unit.

Figure 12 is a side view of several feed units showing the control arrangement and the manner of depositing an insert piece on the conveyor.

Figure 13 is a side sectional view of the conveyor assembly.

Figure 14 is a top partial cut away view of the conveyor showing an end portion of a group of inserts on the moving conveyor.

Figure 15 is a section along line 15 of Figure 14.

Figure 16 is a perspective view of the gathering assembly of Figure 9. Figure 17 is a side detailed view of the gathering units showing the passing of a group to rearranged coupons or inserts.

Figure 18 is a perspective schematic view showing of a paper envelope wrap of the marked and gathered groups of paper inserts.

Figure 19 is a perspective schematic view of the packaging assembly showing the wrap of an outer plastic film about imaged enveloped pieces.

Detailed Description of the Invention

The individualized packet generally indicated at 10 in Figures 1 to 3 has an address face 11, an envelope flap 12, a rear face 14 and adhesively held at side edges 15. The plurality of insert sheets 16 which are all coded with a bar code 17 as illustrated in the cut-away portion of Figure 1. Although an in-line envelope or wrap configuration is shown, an ordinary envelope, in which the insert pieces or coupons are inserted can also be used.

The particular recipient address of whom the packet is to be mailed or delivered is indicated at 18. The return address of the sender is indicated at 19. Another type of packaging or wrap material is shown by the packet 20 in Figures 4 and 5 as a coated thin plastic film wrap. The address face 21 of the packet has a clear longitudinal extending address window 22 and printed return address 23. The longitudinal perforate line 24 is disposed close and parallel to the top fold edge 25 of the wrap. The rear face 26 is folded about fold line 25 to complete the packet with its free edge 27 extending over the lower section 28 and is heat sealed thereto along line 29. Perforate line 30 which is parallel to the folding edge 25, along with perforate line 24 provides a severable tear strip 31 which opens the sealed wrapping to permit removal of the group of inserts 32. The name and address of intended addressee is placed on the outermost insert 33 so that it can be read through the clear opening 22 on the address panel 21 of packet 20, as shown in Figure 4. Ends 34 and 36 are heat sealed.

The system for producing the packets of Figures 1 and 4 is shown in Figures 6. Multiple selective insert or coupon feeders 40 produce variable quantity shingled coupon packet groups 41 on the moving conveyor 42. The feeders are controlled by the system control 43 which interconnects with the conveyor and multiple feeders to permit accurate placement of the individual coupons of each feeder represented by the arrows to the successive groups of insert sheets or coupons as they pass that particular feeder.

When the groups of packets have passed the multiple feeders, they pass under the marking or imaging assembly 44, which places the unique code or marking on each piece of the shingled group as the group passes.

After the group of insert sheets or coupons has been completed the marked group 46 is carried on the conveyor generally indicated at 45 to a pack gather assembly where the shingled spread out group of inserts is reconfigured in a vertical stack as indicated at 47. The reconfigured or gathered inserts are then passed to a packaging assembly 48. Either immediately before packaging or immediately thereafter packaging of the group of inserts or immediately thereafter the outer panel of the wrap receives the corresponding name and address of the recipient for that particular group of inserts by the addressing assembly 49. The completed packet P, corresponding to the items in either Figure 1 or Figure 4 is then separated from the other groups and then collected.

Figure 7 shows in detail the shingled configuration of the coupons or insert pieces generally indicated at 50, after passing the selective feeder assembly. The top sheet 51 is covering all but the lower trailing edge section 52 of the underlying coupon. The imager 53 is shown placing ink jet bar code 54 on trailing sections 52 of all of the underlying pieces as a group of insert pieces moves in the direction of the arrow 55. The addressee bar code is supplied as a series of longitudinally extending parallel lines 56.

Figure 8 shows the pack gathering assembly schematically, where the groups of inserts such as the shingle group 58 held between the lower support conveyor belt 59 and upper hold down conveyor belt 60 are carried between a pair of drive rollers 61 and 62. Drive rollers urge the individual insert piece of group 63 against stationary upper roller 64, and lower roller 65 both of which are operable intermittently to pass the group of inserts between them after the forward edge of all of the inserts have been brought into alignment at 66 by abutting the periphery of upper roller 64. After this occurs, the lower roller 65 is rotated. The free floating upper roller 64 moves upward slightly to accommodate the thickness of the inserts and pass the insert group through the space between the rollers. The aligned group of inserts, such as 68 are then conveyed to the packaging assembly.

An overall perspective view of an entire in-line system is shown in Figure 9. It includes a control system, a selective feed control assembly, a conveyor assembly and a gathering assembly.

The system control assembly includes a data storage bank 70 with the addresses and code information as to the type of inserts for each addressee. It is contained on magnetic tapes or other electronic storage units. A data input section 71 feeds this information, which can be on a sequential basis such as a list of names with corresponding types of inserts to be contained in the packet for that individual. This data is fed into the computer system control unit 72 and subsequently to the assembly control 80. At the appropriate time, it will feed the control signal to the motors operating the selective coupon feeders along line 81. The shaft encoder 74, connected to the conveyor, supplies information on conveyor speed which is coordinated with the data fed to the assembly control 80.

Operation control 76 also inputs to the system control terminals (CPU) 72, receiving input from the manually operated 78, and 79. A mailing control section 77 is also connected to the system control 72. The data output assembly 73 records and prints out the listing of addressees and type of insert packet to be mailed.

The system control computer directly coordinates the signals of the assembly control 80, the imaging control 82, the image verify control 84, and the packaging control 86.

The coupons or insert sheets to be assembled into individualized packs or groups of insert sheets are fed by ribbon feed magazine units generally indicated at 88, each of which is connected to a coupon separation assembly 89 and a coupon dispensing assembly 90. Coupons or insert sheets 91 are released on receipt of a signal from the assembly control 80, which is coordinated with a scanning signal received from a photocell 92 associated with each feeder unit.

The first assembly puts down a keying coupon, the leading edge of which is sensed by following photocells, it is the only coupon that is always contained in all groups. The conveyor assembly includes a horizontal web type conveyor 94 which passes under the feeders. Three feeder assemblies are shown, but, as will be noted further, as many as 150 feeder units or more are used in the feeder assembly.

The conveyor surface 94 has several lines of spaced suction openings 95 on which the coupon items from the feeders are placed. They lie in a shingle or overlap configuration shown in Figures 7, and 8, and as shown on the conveyor adjacent to coupon 91. A vacuum blower assembly 96 maintains a suction through the openings in the lines of holes 95 which holds the insert sheets such as, coupon 91 immovably in position throughout their travel along the conveyor.

Completed groups of inserts pass under the imaging bar 97 of an ink jet imager, such as the admark imager manufactured by Eastman Kodak Company unit, which places thereon a particular bar code for a given addressee as supplied from the system control computer 72, through the imaging control assembly 82, as previously discussed with respect to Figure 7.

A bar code scanner disposed immediately behind the imaging bar 97 senses the bar code applied by the ink jet imager bar 97 and passes the signal back through the image verify control system 84. A dryer unit 98 dries the ink, preparatory to the packaging of the inserts.

The conveyor system 100 has a separator plate 101 that separates the inserts at the end of the conveyor 94, they then are carried by the lower belt 102 and the upper belt 103. At the end of the conveyor system 100, the shingled group of inserts 104 enters the gathering assembly 106 which has been described with respect to Figure 8. The aligned coupons 107 are then fed into a commercial type envelope inserter 108 which produces a finished packet 109, such as that shown in Figure 1.

Figure 10 is a much reduced schematic top view of the feed and conveyor assemblies. The conveyor 110 is supported in horizontal position by support assemblies 111. Plural feed units are disposed approximately one foot apart form each other. Twenty units are shown, but preferably 150 or more units are arranged along the conveyor to provide the selective variety of insert and coupon pieces for a large variety of products in national distribution. The feed unit 114 is supplied with coupon or insert pieces by a ribbon containing successive coupon pieces which are separable from each other along a transverse perforate line. The ribbon is shown in Figure 11. Ribbon storage containers 116 and 118 supply the ribbon to feeder 114. The ribbon is folded back on itself along the perforate lines when in the container and is fed out of the container from top to bottom. The lower end of the container of the ribbon in container 116 is connected to the upper end of the folded ribbon in the container 118 as illustrated in Figure 11.

The ribbon feed containers are grouped as indicated at 120, 122, 124, 126, and 128. The ribbon containers are held in a common containing unit generally indicated at 130 and shown in Figure 11.

The container assembly generally indicated at 130 is an elongated box 132 which has a ribbon container 134 for the long over-folded ribbon 135. The line of connected identical insert sheets or coupons is fed out as a continuous ribbon with successive coupons, such as 136, 137, and 138, which are separable along the transverse perforated fold which divides each of the inserts from each other. They are also folded back on each other in the container 134 along that fold line. The end of the ribbon 139 in container 134 is attached to the leading edge of the over-folded ribbon in container 140, so that the top end portion can be pulled out of its container to provide a continuous ribbon feed to the feed units after the ribbon 135 has been emptied out of container 134.

The trailing edge 148 of the insert containing ribbon of container 140 is similar to the trailing edge 139 and can be attached to additional ribbons to provide for a long running continuous operation. The manner in which the end portion of the ribbon is disposed within container 140 is shown in dotted outline. As with ribbon 135, the end of the ribbon in container 140 extends upwardly from the bottom of the box along the rear side, with the last three insert pieces being 144, 146 and 148. Figure 12 is a side view of the feed and conveyor assemblies demonstrating the operation of the feeders. The feeder assembly generally indicated at 150 both separates each of the insert coupons from its ribbon 151 and then accurately places such coupon on the conveyor at the exact location required. The ribbon 151 is supplied from the ribbon containers shown in Figure 11 as a straight in-line feed, such as generally illustrated at 115 in Figure 10. The feed assembly 150 corresponds to feed unit 114 of Figure 10.

The continuous ribbon is supplied to the coupon separator wherein it is engaged by rollers 152 and 153, and then passes over an off-set wheel 154 and between a second set of engaging rollers 155 and 156. Both sets of rollers tightly engage the ribbon and are spaced so that the transverse perforated line separating each successive insert sheet or coupon would be positioned over roller 154 at 157. A separating force due to different roller surface speeds is exerted on the ribbon as it moves through the rollers an over the roller 154. When the perforate line, which has been folded in the container to additionally weaken it, moves over the roller 154 which is off-set from the normal line of travel, the leading insert piece is separated from the ribbon along that perforate line at roller 154.

Sensor photocell 158 detects the presence of the leading edge of the separated coupon and transmits this control signal along line 159 to the computer or microprocessor 160. In the event that the supply of ribbon to the feed of unit is interrupted, the detector will indicate this to the computer 160 (in Figure 9 CPU is 72) .

The computer 160 receives its information on the movement of the conveyor along line 161, from the shaft encoder 162 connected to the conveyor drive wheels. It will give the speed of the conveyor belt 164 and the packet of inserts, such as 166, carried by it. Motor drive control circuit 168 is actuated by a signal supplied along line 167 from the computer 160. The control assembly 168 controls both the separator assembly, and the coupon feed assembly 170. The motors powering both of the feed units are fast acting electronic stepper motors. The coupon or insert 172 is grasped between the spring biased roller 175 and the larger driven base roller 174 which when activated to feed the conveyor. The curved metal guide chute 176 and coact to guide the insert from the feeder assembly and out onto the belt. The coupon feed photocell 178 provides an electronic signal which is supplied along line 179 to the central computer 160 to indicate delivery of the coupon.

The photocell 180 indicates, by a signal along line 181 connected to the computer when an insert from the feeder is to be placed on coupon group 182. The photocell 180 senses both the leading and trailing edge 183 and 184, of the uppermost and lowermost coupon and transmits this information to the computer 160 which has information on the number of inserts in that packet previously supplied to that group at that time. The inserts are laid down with an overlap or shingle configuration, as shown, with the exposed end section width being at least three eighths of an inch for each insert. On this shaft the computer knows the overall speed of the conveyor from the encoder and the distance to the projected leading edge of the new coupon to be added to the group by that feeder. The time interval is calculated and the feed control pulse given at the end of that interval.

It should also be noted that the feeder assembly may or may not be activated to deposit an insert on the group. If the coupon group is not to receive the particular insert carried by that feeder, there will be no activation of that feed assembly. This is controlled by the data input material to the computer which has data on coupons to be contained in each unique group for its corresponding addresses. If no insert from that feeder is to be received by that group, the coupon feed unit will not be activated.

Photocell 186 is similar in function to photocell 180. It has the sensing control function for the next feeder assembly, sending its signal along line 187 back to the computer to control operation and timing of that unit.

The control unit 188 for the following separator assembly 190 is connected to the computer 160 along line 189. The feeder assembly receives the ribbon of coupons which is threaded between rollers 192 and spring-biased wheel 193, then off-set over and around the large idler wheel 194 and between drive wheel 195 and spring biased idle wheel 196. The periphery of the second drive wheel 195 moves at a slightly faster speed than drive wheel 192, exerting a force which separates the coupon from the ribbon along the perforated line connecting it to the following coupon, when it reaches point 197 along wheel 194.

The photocell 198 is used to sense the presence or absence of the coupon in similar fashion to that described for photocell 158 of the previously described figure assembly 150, 170. The coupon feed assembly 200 consists of a lower drive wheel 202 and spring biased idler wheel 203, which will hold the separated coupon ready for delivery when an activating signal is received from the control circuit 188. The hold down assembly 204 guides the coupon 207 out onto the belt where its leading edge 208 will be laid down on the belt and held in position along its leading edge of the suction force exerted through the suction in the conveyor belt openings. The control system is sufficiently accurate to permit a lay down of 44 or more coupon or insert pieces. The design overlap exposure is a minimum of three eighths of an inch. To maintain the correct tolerance, the photocell 209 senses a leading edge 208 of the last piece layed down to determine how close to nominal dimension was the coupon layed down. If a present limit is exceeded, a compensation is made through the computer to adjust that feeder for the next coupon it feeds.

Figure 13 is a cross-sectional view of the conveyor having a vertical support 210 mounted on the horizontal section 211, supported by adjustable feet 212. Threaded adjustable feet 214 and 215 are also shown.

A vacuum duct 216 is connected at 217 to a vacuum plenum 218 mounted to the bottom of the conveyor web assembly generally indicated at 220. The plenum engages two depending vertical side plates 221 and 222 which depend from the horizontal bed plates 219. The other end of the duct not shown is connected to a blower, as shown in Figure 9.

The conveyor belt 240 moves along the top of this elongated structure with its side sections supported by two elongated and parallel vacuum suction slot assemblies. An elongated support member 223 is spaced from the side support element 221 to provide an elongated suction slot connecting to the plenum 218. A second and parallel member 227 parallel and spaced from member 223 forms a second elongated suction slot 229 parallel and close to elongated suction slot 225.

Suction slots 224 and 226 are similarly formed by elongated members 228 and 230. As shown in Figure 14, which is a top partially broken away section of the web on the support members and disposed over plenum 218, it will be seen that the rows of suction holes in the web are in direct alignment with the elongated suction slots 224, 226, 225 and 229.

Shaft and pulley 234, 236 are mounted through the upright 210 and bearing 235 to support a sprocket or driving spur gear at the end of the conveyor shown in dotted outline.

The conveyor belt generally indicated at 240 has a flat top configuration, and is shown in Figure 14 has two longitudinally extending rows of holes on each side which are aligned with the elongated suction slots connecting to the interior of the vacuum plenum 218.

Figure 14 is a top cut away view of the conveyor showing the leading section of a group of insert coupons held in position on the conveyor. The longitudinally extending row of holes 242, 243 and 244 in the belt are aligned directly over the longitudinal suction slot 225, and the openings 245, 246, 247 are part of a line of holes that are directly aligned with the parallel suction slot 229. It will be seen that the two rows of suction holes are staggered with respect to each other.

The other side of the web has a similar longitudinally extending row of suction holes 248 and 249 aligned with suction slot 224 over which they travel in the course of the conveyor movement. The off-set parallel row of suction holes 250, 251 and 252 are aligned with and travel along suction slot 226.

The cross-sectional view of the web along line 15 at Figure 14 shows the central drive element 256 with a tooth configuration 258 which is integral with the central under surface of the belt and fits between vertical support pieces 227 and 228 as illustrated in Figure 15. The tooth configuration matches that of the spur gear 238 with which it meshes for driving the belt.

This belt and vacuum plenum construction permits the use of a long length of belt suction surface all of which is vacuum active, while precluding large vacuum losses that would otherwise make such an approach to holding down items on the belt impossible.

At any point along the belt a paper insert can be deposited with assurance that the vacuum applied through the openings are sufficient to hold it rigidly in place.

Figure 14 and Figure 15 both illustrate how the group of inserts 260 are held in position along the leading section of each insert. Insert 261 is held in position by holes 245 and 249, insert 262 is held by holes 243 and 251. Inserts 263, 264 and 265 are similarly held by their succeeding holes upon which they are placed.

The length of the belt for the selective distribution purpose in the typical application for which it was designed is approximately 150 feet. Six blower units are used to maintain the necessary vacuum along the entire length of the belt. The belt is a fast moving belt moving at approximately 400 feet per minute.

The gathering assembly is shown in general perspective in Figure 16. The completed group of sheet inserts or coupons 269 moves along to the end of the -26- conveyor, where suction plenum 218 ends, and then under the hold down belt unit 270, 271, 272. The lower portion of the belt 275 passes under hold down roller 273 to hold the inserts in position over the large rotating wheel 278. The pin elements on the outer periphery lift the leading edge of the coupon by extending the pins through the suction holes or the belt an air nozzle provides a jet of air to lift the coupons and to complete the separation of the coupons from the assembly conveyor. Metal support piece 277 coacts with the drum 278 to effect removal. The thin central conveyor belt 279 together with the lower belt section 275, is held in position against the top of the inserts by roller 280 which is pressed against the lower support roller 282, which, is indicated in Figure 17, on the drive elements of the gathering assembly. Roller 280 has a resilient outer rubber periphery to allow for the varying widths of insert groups, the lower surfaces of which it engages and urges in a forward direction moving the forward edge 285 of each successive insert against the stationary periphery of the spaced rollers 286 and 287, mounted on common shaft 288. This roller assembly is spring biased downwardly by spring 289 to exert a force which holds end tight engagement with corresponding wheels 290 and 291 disposed on either side of the retaining belts to 275 and 279. Lower drive wheels 290 and 291 are connected to the drive motor 292. When the insert pieces of group 284 are brought into vertical alignment the forward edges of the inserts engage the nip between the wheels 286 and 290. After this occurs, the motor 292 is actuated and the rollers move the packet 284 between them as shown in Figure 17 with the upper rollers 286 and 287 moving slightly upward on their pivoted support arms against the spring 289. Until the wheels are actuated by the drive assembly, they act as a stop to keep the sheets of the group from moving forward.

The belt section 275 is held downwardly against the aligned group of inserts 296, then past through the gatherer assembly. The inserts are now supported by belts 297 and 298 and will then be carried through the packaging assembly. Insert group 300, with is forward edges 301 aligned, is carried by the belt 304 mounted on wheel 305 carries the inserts to the packaging assembly. -28-

In addition to the option of the envelope inserter, which is a standard piece of commercial equipment shown in Figure 9, there is the possibility of wrapping the coupon groups as part of a continuous in-line wrap operation. Figure 18 shows the use of paper stock to address and enclose each group of coupons or insert.

The inserts 312 pass from the intermediate conveyor belt 303 and are moved on intermediate conveyor as shown at 314 and 316 to web 318 from a roll of stock 320. Before moving up and under the oncoming groups of inserts the wrap web 318 is passed around a turn bar 322 where its outside surface passes under an address imager 324 which applies the address of the intended recipient. The other inner side of web 318 passes under a flexo glue applicator generally indicated at 326 which applies a series of glue lines 327 and 328 configured to form the transverse glue line for the end of each wrap envelope, as well as longitudinal glue line for closing the envelope after the fold operations 322 and 324 close the packet wrap about the coupon groups. A press wheel 336 presses the two end sections of the web 318 into contact gluing them together. A cutter 338 disposed opposite an anvil cylinder successively cuts pieces from the web when its blade is rotated into engagement with the web to transversely cut off a packet 340 which is carried with a conveyor 342 be collected and shipped.

Figure 19 discloses a method of using a plastic film wrap for the inserts. The inserts leaving the gathering assembly 272, 302, 303 are carried by conveyor to the wrap material. It is plastic film plastic stock optionally clear or coated with an opaque substance and having a linear clear strip 352. It has two parallel light perforated lines 254 and 255 imprinted by the dual perf unit 356. The web passes under the turn bar and up over conveyor 360 so that insert group 361 can be received by inner surface 359 of the web, and positioned to pass under imager 362 which places the name and address of the recipient 363 on the uppermost insert piece of the group. Subsequent fold operations at 364 and 365 bring the two edge portions into superposed position where heat sealer 366 applies a heat sealed line to longitudinally close the wrap of plastic film about the inserts. A heated cutter-sealer unit generally indicated at 368 closes the ends of the plastic wrap and severs each insert piece.

In this arrangement, the entire packet and all of its inserts are to be coded with information which can subsequently be machine read to permit sorting of returned coupon pieces.

A coding assembly 370 where each completed packet 371 is supplied by a laser 372 which makes a linear series of spaced holes 373 through the entire packet. The correlation of the addressee and the packet is controlled by the computer circuitry of the packaging and control circuits shown in Figure 9. Finished packet 376 corresponds to the packet of Figures 4 and 5.

With this ability to match addressee with only those coupons of particular interest it is possible to target special groups or individuals. Further, it is possible to machine read returned coupons to determine those on the mailing list who used the coupons.

Claims

HAT IS CLAIMED IS

1. A system for producing an individualized packet, comprising: a) a linear conveyor assembly for receiving insert pieces which are to be placed thereon to form a series of longitudinally spaced groups; b) a plurality of successive spaced insert piece feeder assemblies disposed adjacent the conveyor for supplying different insert pieces to build individualized groups of insert pieces as they move past the feeder assemblies on the conveyor assembly; c) control means connected to the conveyor and the plurality of feeder assemblies for controlling the dispensing of insert sheets from the feeding assemblies to the spaced groups of insert pieces on the conveyor; d) a master control data assembly connected to the control means for producing a control signal for specific feed assemblies to control their supply of an insert sheet to a given group of insert sheets as it moves past that feed assembly; e) a marking assembly disposed adjacent the conveyor for individually marking all of the sheets of each group with a common marking for that group to distinguish that particular group from the other groups, and f) a packaging assembly disposed adjacent the conveyor for receiving the successive groups of sheets downstream of the feeder assemblies to form an individualized self-contained packet for each group.

2. The system for producing an individualized packet as set forth in claim 1 wherein: a) printing means is disposed adjacent the packing assembly for providing a readable identifying marking on the outer surface of the packet corresponding to the individualized group of paper inserts within the packet.

3. The system for producing an individualized packet as set forth in claim 1 wherein: a) the feed assemblies include means for controlling the feed of each sheet to its assigned group of sheets in an overlap arrangement to leave a small end section of the sheet immediately below it exposed.

4. The system for producing an individualized packet as set forth in claim 3 wherein: a) the lay-down pattern of the feed system brings about a shingle configuration for each group of sheets which builds in the direction of conveyor travel such that a small transverse end section of all sheets in the group are not covered by sheets subsequently placed on them thereon.

5. The system for producing an individualized packet as set forth in claim 1 wherein: a) the feed assemblies respond to signals from the control means to produce individualized packets which correspond to a preselected individual listing contained in the master control data assembly.

6. The system for producing an individualized packet as set forth in claim 4 wherein: a) the conveyor assembly includes holding means for holding the dispensed sheets groups of sheets in position on the conveyor and which does not cover any of the exposed end sections of the groups.

7. The system for producing an individualized packet as set forth in claim 6 wherein: a) the conveyor assembly includes a continuous conveyor belt; b) the hold down means includes a pneumatic vacuum assembly associated with a line of openings in the belt under the sheets to pneumatically hold them in an immovable position on the conveyor belt.

8. The system for producing an individualized packet as set forth in claim 1, wherein: a) the marking assembly includes a transversely disposed ink-jet imaging bar which applies a common bar code marking on all of the exposed end sections of the dispensed sheets contained in each group.

9. The system for producing an individualized packet as set forth in claim 1 wherein: a) the master control data assembly includes a list of addressees with a control coding for determining controlling selection of the number and type of sheets in a group corresponding to a particular addressee.

10. The system for producing an individualized packet as set forth in claim 1, wherein: a) the multiple feed assemblies include an optical scanner for sensing the approach of a group of insert sheets.

11. The system for producing an individualized packet as set forth in claim 3, wherein: a) a gathering assembly is disposed adjacent the conveyor beyond the marking assembly for changing the exposed end section configuration of each group to a superposed stack where the edges are vertically aligned to permit packaging.

12. The system for producing an individualized packet as set forth in claim 1, wherein: a) the packaging assembly includes a commercial envelope inserter unit.

13. The system for producing an individualized packet as set forth in claim 1, wherein: a) the packaging assembly includes an in-line wrapper means for receiving successive groups of inserts or coupons on a web and enclosing the web about the groups and subsequently severing each enclosed group from the web as an individual packet.

14. The system for producing an individualized packet as set forth in claim 13, wherein: a) the in-line wrapping means includes imaging means for placing the address of the intended recipient of a given corresponding packet on the section of the web which will form an envelope panel of the finished separated packet.

15. The system for producing an individualized packet as set forth in claim l, wherein: a) feeder assemblies includes supply means supplying a preprinted ribbon of coupons which are individually separable from the ribbon by the feeder assembly.

16. The system for producing an individualized packet as set forth in claim 11, wherein: a) the gathering assembly includes a stop unit against which the forward edges of the coupons or inserts are urged; and, b) mechanical means engages the rear edges of the coupons or inserts for urging them into contact with the stop unit.

17. A system for producing an individualized packet, comprising: a) a feed assembly for supplying a plurality of paper ribbons of successive printed advertising coupons or inserts separating the coupons from the ribbons for placing them on a conveyor; b) a linear conveyor for receiving the separated insert pieces from the plurality of ribbons to build spaced successive groups of coupons; c) the conveyor assembly includes holding means for holding each of the sheets from the feeding means in a fixed position with respect to the conveyor and other sheets of the group of sheets with which it is associated; d) a common marking assembly for placing an identification on each coupon or insert in each group of coupons to distinguish it from other groups of coupons or inserts; e) a packaging assembly for receiving each of the groups of coupons and placing each group in a closed mass distributable container; and, f) a marking assembly for placing a readable identification on the container that is matched to correspond with that particular group of inserts.

18. A system for producing an individualized packet as set forth in claim 17, wherein: a) holding means includes a pneumatically operated assembly for holding the coupons or inserts deposited on the conveyor in fixed position during the course of their travel on the conveyor.

19. The system for producing an individualized packet as set forth in claim 18, wherein: a) the hold down means on the conveyor includes a longitudinally extending line of openings through the belt through which suction is applied to hold the sheets in position on the belt.

20. The system for producing an individualized packet as set forth in claim 17, wherein: a) a plurality of containers holding over- folded coupon containing ribbons are arranged to feed plural parallel lines of ribbon containing coupons to the feeder assembly.

21. The system for producing an individualized packet as set forth in claim 17, wherein: a) the feeder assembly includes means for separating the successive coupons in each ribbon from that ribbon.

22. The system for producing an individualized packet as set forth in claim 21, wherein: a) the feed assembly includes two pairs of spaced gripping roller assemblies and an intermediate stress concentration element for separating each coupon along a transverse perforate line separating the coupons from each other.

23. The system for producing an individualized packet as set forth in claim 17, wherein: a) the feed assembly includes sensing means for determining whether a coupon or insert is in position to be dispensed by the feeding means.

24. The system for producing an individualized packet as set forth in claim 21, wherein: a) the feed assembly includes a plurality of mechanical separator and coupon feed units aligned and positioned along the length of a receiving conveyor assembly for producing a series of separate successive groups of inserts or coupons which are distinct from one another.

25. The system for producing an individualized packet as set forth in claim 24, wherein: a) a control assembly is associated with each feed unit for controlling the dispensing of a coupon or an insert from that feed unit; and, b) a sensing assembly is disposed adjacent each feed unit and connected to the control means for sensing the approach of a group of inserts to its associated feed unit and sending a signal to the control assembly.

26. The system for producing an individualized packet as set forth in claim 25, wherein: a) all of the inserts in each group on the conveyor are held in position pneumatically.

27. The system for producing an individualized packet as set forth in claim 26, wherein: a) the conveyor assembly shows a horizontal web belt having a line of openings therethrough; and, b) a vacuum plenum is disposed below the belt and is connected through a linear vacuum slot which extends along the line of travel of the line of holds through the conveyor belt.

28. The system for providing an individualized packet as set forth in claim 27, wherein: a) the conveyor assembly includes an exhaust blower unit for providing a vacuum in the vacuum plenum.

29. The system for producing an individualized packet as set forth in claim 27, wherein: a) the feeder units deposit the coupon or insert sheets in a shingled configuration; and, b) the marking assembly is activated to supply an identical bar code marking along the entire overlapped section of the shingled group of coupons or inserts.

30. The system for producing an individualized packet as set forth in claim 17, wherein: a) a printing assembly is disposed adjacent the packaging assembly for providing a readable identifying marking on the outer surface of the packet which places the name and address of the recipient to receive a given set of coupons or inserts.

31. The system for producing an individualized packet as set forth in claim 17, wherein: a) the feed assembly includes means for controlling the feed of each sheet through the conveyor of the conveyor in an overlap arrangement to leave a small end section of the previously deposited coupon or sheet uncovered.

32. The system for producing an individualized packet as set forth in claim 31, wherein: a) each coupon or insert sheet is held in position on the conveyor by a positive force applied to a portion thereof.

33. The system for producing an individualized packet as set forth in claim 32, wherein: a) a positive force is applied to the coupon or insert sheets as a suction force applied from beneath the conveyor.

34. The system for producing an individualized packet as set forth in claim 17, wherein: a) the feed assembly includes a plurality of feed units each of which dispense a different coupon or insert; and, b) a control assembly including a data storage unit having a list of addressees and corresponding types of inserts for such addressee is connected to the feed assembly for producing individualized packets for each addressee.

35. The system for producing an individualized packet as set forth in claim 34, wherein: a) each of the feed assemblies has its individual optical scanner for sensing the leading edge of an approaching group of coupons or inserts.

36. The system for producing an individualized packet as set forth in claim 35, wherein: a) a gathering assembly is positioned adjacent the conveyor beyond the marking assembly for changing the shingle overlap configuration of each group to a superposed stack where the edges are lined to permit packaging.

37. The system for producing an individualized packet as set forth in claim 36, wherein: a) the gathering assembly includes a pair of intermittently acting stop rollers against which the forward edges of the coupons or inserts in that group are forced to bring them into superposed relationship prior to activation of the rollers to pass the entire reconfigured group of coupons or inserts when the rollers are actuated; and, b) a pair of continuously acting rollers disposed upstream of the intermittently acting rollers at a distance less than the length of the coupon or insert pieces engages and successively moves each of the coupons or insert pieces in that group against the intermittently actuated rollers.

38. The system for producing an individualized packet as set forth in claim 37, wherein: a) the packaging means includes an envelope inserted.

39. The system for producing an individualized packet as set forth in claim 17, wherein: a) the packaging assembly includes an outer wrap in-line paper sheet folding and cutting assembly; and, b) addressing means disposed adjacent the outer wrap for printing the address of the addressee- for which a given packet is to be forwarded.

40. The system for producing an individualized packet as set forth in claim 17, wherein: a) the packaging assembly includes an assembly for providing a plastic film outer wrap for enclosing the groups of coupons which has a clear transparent section; and, b) printing means for printing on the outer surface of the insert outer position viewable through the transparent section of the outer wrap, the address of the individual to which that particular packet is to be forwarded.

41. The system for producing an individualized packet as set forth in claim 17, wherein: a) the marking assembly places an identical bar code marking on each coupon or insert of a group which distinguishes them from inserts or coupons in other groups.

42. The system for producing an individualized packet as set forth in claim 17, wherein: a) the packaging assembly includes an industrial laser for placing a coded line of spaced holes through the entire packet which is machine readable feeder; and, b) control means for activating the dispensing mechanism for each.