Envelope Flap Printing with Single Print Engine
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high-speed commercial inserting machines face challenges in printing information on both the front face and flap of envelopes in a single pass, often requiring separate print engines and struggling to compensate for variations in mail piece thickness, which can affect print quality.
Innovation Solution
A method and apparatus that feed an envelope past a single top-down print engine with the flap open, allowing for simultaneous printing on both the front face and flap in a single pass, followed by inserting a collation and sealing the envelope, utilizing a transport mechanism, flap-opening mechanism, printing mechanism, inserting mechanism, and control mechanism to streamline the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate print engines are provided for front face and flap printing, then printing capability on both surfaces is improved, but device complexity increases
Solution Approach 1:
A single print engine is designed to perform multiple functions by printing on both the front face and flap of the envelope during one pass. The print engine is positioned and configured to access both surfaces sequentially, eliminating the need for separate print engines while maintaining full printing capability on all required envelope surfaces.
Solution Approach 2:
The patent combines the front face printing function and flap printing function into a single integrated print engine operation. By merging these two previously separate functions into one device, the system reduces complexity while preserving the ability to print on both surfaces of the envelope.
2Manufacturing precision
If downstream printing is performed to compensate for thickness variations, then print quality is improved, but productivity decreases
Solution Approach 1:
The print engine performs printing operations on the envelope flap and front face before the collation is inserted into the envelope. By completing all necessary printing actions in advance, before the mail piece thickness is altered by insertion, the system eliminates the need for downstream repositioning or compensation mechanisms, thereby maintaining both high print quality and high productivity.
3Device complexity
If a single print engine is used for both front face and flap printing, then device complexity is reduced, but printing precision may deteriorate
Solution Approach 1:
The printing process is segmented into distinct phases: first printing on the envelope flap, then printing on the front face. The single print engine is positioned to sequentially access each surface during one pass through the envelope. This segmentation allows the print engine to maintain precise control over each printing operation independently, ensuring high printing precision despite using a single device.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method includes feeding an envelope along an envelope transport path (102) in a paper-handling machine (100) to a flap-opening station (106). The method further includes opening the flap of the envelope at the flap-opening station (106) and printing (108) on the envelope with the flap in an open position. After printing, a collation is inserted into the envelope.