Buckle Folder Envelope Folding for Mailpiece Jam Reduction

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Solution Overview

Problem

Existing systems for creating mailpieces with printed insert materials suffer from frequent paper jams, mailpiece damage, and adhesive hygiene issues due to the use of pre-assembled envelopes and complex motion controllers.

Innovation Solution

A system that automates the creation of mailpieces by folding a continuous web of paper to form envelopes around printed insert materials, using a buckle folder and a mechanical linkage system to control the insertion and folding process without pre-assembled envelopes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If pre-assembled envelopes are used in inserting machines, then mailpiece creation can be automated, but frequent paper jams and mailpiece damage occur

Engineering Contradiction:

Improveautomation of mailpiece creationVSAvoidpaper jams and mailpiece damage

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

Instead of inserting pre-assembled envelopes through a complex inserting machine, the patent inverts the process by folding the envelope around the insert materials. The envelope sheet is fed continuously and folded in a buckle folder mechanism, eliminating the need for pre-assembled envelopes and complex insertion mechanisms, thereby reducing paper jams and damage

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts and eliminates the pre-assembled envelope component from the system. By feeding loose envelope sheets and folding them around inserts, the system removes the problematic pre-assembled envelope handling step that caused frequent jams and damage in traditional inserting machines

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If pre-assembled envelopes are stored and manually loaded, then envelope availability is ensured, but significant manual labor is required

Engineering Contradiction:

Improveenvelope availabilityVSAvoidmanual labor for loading

Core Design Contradiction:

Ease of operationVSExtent of automation

Solution Approach 1:

The system feeds loose envelope sheets automatically from a hopper through the buckle folder mechanism without requiring manual loading of pre-assembled envelopes. The continuous feeding and folding process eliminates the need for operators to manually load envelopes, significantly reducing manual labor while ensuring continuous envelope availability

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Envelope sheets are prepared in advance as loose sheets and stored in a hopper, ready for automatic feeding. This preliminary preparation eliminates the need for manual assembly and loading operations, allowing the system to operate continuously with minimal human intervention

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If envelopes are stopped at specified positions for insertion, then precise insertion positioning is achieved, but processing speed decreases

Engineering Contradiction:

Improveinsertion positioning accuracyVSAvoidprocessing speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The buckle folder mechanism operates continuously without stopping the envelope sheet at specified positions. The envelope is folded around the insert materials in a continuous motion, eliminating idle stopping time and maintaining high processing speed while achieving precise folding and positioning through the mechanical folding action

Inventive Principle:

Principle #20Continuity of useful action

4Ease of manufacture

If adhesive is dispensed on envelope sheets, then envelope sealing is achieved, but adhesive hygiene issues occur due to misfeeding

Engineering Contradiction:

Improveenvelope sealingVSAvoidadhesive hygiene issues

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The buckle folder acts as an intermediary mechanism that ensures proper positioning and alignment of the envelope sheet before adhesive application. By mechanically folding and securing the envelope in the correct position, it prevents misfeeding that would cause adhesive to be dispensed on wrong areas, thereby eliminating adhesive hygiene issues while maintaining effective sealing

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3717389B1Methods and systems to create a mailpiece with an inline buckle folder

Publication Date: 2025.02.12 BELL & HOWELL CO

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AI summary

Systems and methods of forming a mailpiece by folding an envelope sheet (310) around one or more insert sheets (322, 324) e.g., an insert stack, include creating the insert stack, staging the insert stack in an insert stager (35) proximate to the transport path (20) of the envelope sheet (310), dispensing the insert stack onto the envelope sheet, applying adhesive to the envelope sheet in the adhesive application region (45), using a buckle folder system (50) to wrap the envelope sheet at least partially around the insert stack to form an unsealed envelope without stopping the envelope sheet and without bending the insert stack, folding the envelope flap of the unsealed envelope onto the back thereof using a plow folder, and sealing the flap of the envelope to the back of the envelope, creating the mailpiece.