Integrated Mailpiece With Nested Return Envelope

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Solution Overview

Problem

Current mail production systems face inefficiencies and increased costs due to the need for separate manufacturing and insertion of outbound and return envelopes, which limits throughput and requires larger return envelopes, leading to higher paper usage and costs.

Innovation Solution

A method and system for creating an integrated mailpiece by printing both outgoing and return envelope information on a continuous paper roll, allowing for a smaller return envelope to be inserted and wrapped within the mailpiece, using a wrapping document processing system that applies glue and perforations to form a sealed, folded mailpiece.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate manufacturing and insertion of outbound and return envelopes is used, then each envelope can be manufactured independently, but the process complexity increases and throughput decreases

Engineering Contradiction:

ImproveIndependent envelope manufacturingVSAvoidMailpiece throughput

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines the outbound envelope and return envelope into a single integrated mailpiece structure. The return envelope is inserted into the outbound envelope in a continuous flow process, eliminating the need for separate manufacturing and insertion steps. This merging of functions allows both envelopes to be produced simultaneously in one pass through the processing system, directly resolving the contradiction between independent manufacturing capability and overall throughput.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated mailpiece design allows a single processing system to perform multiple functions: creating the outbound envelope, inserting the return envelope, and preparing the complete mailpiece for delivery. This multi-functional approach eliminates the need for separate dedicated systems for each envelope type, thereby improving productivity while maintaining manufacturing flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If separate manufacturing of return envelope is used, then return envelope can be produced independently, but additional costs and material usage increase

Engineering Contradiction:

ImproveIndependent return envelope productionVSAvoidPaper usage

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent merges the return envelope with the outbound envelope into a single integrated structure. The return envelope is inserted into the outbound envelope in a continuous flow process, eliminating the need for separate manufacturing and insertion steps. This merging of functions allows both envelopes to be produced simultaneously in one pass through the processing system, directly resolving the contradiction between independent manufacturing capability and overall throughput.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The return envelope is nested within the outbound envelope, creating a compact integrated structure. This nesting arrangement allows the smaller return envelope to be contained within the larger outbound envelope, reducing overall material usage while maintaining the functionality of both envelope types. The nested structure eliminates redundant material and reduces paper usage compared to separate envelope production.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of operation

If larger return envelope is used to accommodate full width stub, then all return information fits, but paper costs increase

Engineering Contradiction:

ImproveReturn slip accommodationVSAvoidPaper usage

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent applies local quality by providing different levels of detail and functionality in different sections of the integrated mailpiece. The return envelope section is optimized for containing return information and stubs, while the outbound envelope section provides the necessary mailing functionality. This localized optimization allows each section to be sized appropriately for its specific function, reducing overall paper usage while maintaining operational effectiveness.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces paper costs, improves efficiency by eliminating separate manufacturing steps, and enables the creation of mailpieces with both outbound and reply envelope functionality in a single process, enhancing throughput and reducing material usage.

Implementation Method 1

The folded paper is sealed along one of more adhesive portions positioned along one or more side edges of the folded sheet

Methodology Applied

Scientific EffectAdhesive: Adhesive

Implementation Method 2

a wrapping document processing system that applies glue and perforations to form a sealed, folded mailpiece

Methodology Applied

Scientific EffectPerforation:

Data Source

PatentUS9688439B2Mailpiece with personalized communication and return slip and related method utilizing wrapper system

Publication Date: 2017.06.27 BELL & HOWELL CO

AI summary

The present teachings relate to a mailpiece and method for assembling a mailpiece using a document processing system such as a wrapper system. The assembled mailpiece has outgoing and reply envelope functionality. In the outgoing format, the mailpiece may optionally contain advertisements, inserted documents, or coupons.