CONNORS, Amy (880 Banning Road, Dawson, Pennsylvania, 15428, US)
JONES, Timothy (122 Roundtop Circle, Scottdale, Pennsylvania, 15683, US)
KOONTZ, Christopher (136 St. Clair Street, Mt. Pleasant, Pennsylvania, 15666, US)
DUDIK, Darrel (1056 Valleyview Drive, Latrobe, Pennsylvania, 15650, US)
CONNORS, Amy (880 Banning Road, Dawson, Pennsylvania, 15428, US)
JONES, Timothy (122 Roundtop Circle, Scottdale, Pennsylvania, 15683, US)
KOONTZ, Christopher (136 St. Clair Street, Mt. Pleasant, Pennsylvania, 15666, US)
CLAIMS What is claimed is:
1. A measuring gauge for determining whether envelopes meet predetermined specifications, the measuring gauge comprising: a first body; a second body protruding from the first body; a first indicia located along a side of the first body for indicating an in or out of specification of a first portion of an envelope; a second indicia located on the second body for indicating an in or out of specification for a second portion of an envelope; and a third indicia located on a side of the first body opposite from the first indicia for indicating an in or out of specification for a third portion of an envelope.
2. The measuring gauge of Claim 1, wherein the second body is an angular protrusion at a right angle to the first body.
3. The measuring gauge of Claim 1 , wherein the second body is a triangle.
4. The measuring gauge of Claim 1, wherein the first body is rectangular.
5. The measuring gauge of Claim 4, wherein the first indicia is located along a first long side of the rectangular first body; and wherein the third indicia is located along a second long side of the rectangular body.
6. The measuring gauge of Claim 1, further comprising: a transparent section located lengthwise between the first indicia and the third indicia for indicating an in or out of specification for a fourth portion of an envelope.
7. The measuring gauge of Claim 1, wherein each indicia are comprised of at least two different bands representing different in or out specifications for a respective portion of the envelope.
8. The measuring gauge of Claim 7, wherein the different bands differ in color.
9. The measuring gauge of Claim 7, wherein the different bands differ in at least one of contrast, pattern, and shading.
10. The measuring gauge of Claim 7, wherein a first band represents an out specification that is too small for the respective portion of the envelope; wherein a second band represents an in specification for the respective portion of the envelope; and wherein a third band represents an out specification that is too large for the respective portion of the envelope.
11. The measuring gauge of Claim 10, wherein the first band and the third band are the same color.
12. The measuring gauge of Claim 7, wherein a first band represents an out specification for the respective portion of the envelope; and wherein a second band represents an in specification for the respective portion of the envelope.
13. The measuring gauge of Claim 7, further comprising: text located on one or more of the indicia for showing its respective portion of the envelope to test.
14. The measuring gauge of Claim 7, wherein at least one of the first body and the second body are configured to be insertable between flaps of an envelope.
15. The measuring gauge of Claim 14, wherein at least one of the first body and the second body are formed of a thin, flexible material to allow the at least one of the first body and the second body to be insertable between the flaps of the envelope at a position where the flaps of the envelope meet and overlap.
16. A method of manufacturing diagonal seam envelopes in a production line, each of the envelopes having a back flap and a front flap joined at a bottom fold, and first and second side flaps joined to said back flap at first and second side folds such that they form a diagonal seam in relation to the body of the envelope, an adhesive material securing the back flap to the first and second side flaps, and utilizing a measuring gauge having a first body and a second body protruding from the first body, the measuring gauge having indicia disposed along side edges thereof that may be read by a user to ascertain whether a portion of an envelope is within predetermined specifications, the method comprising: selecting at least one test envelope during a production run for measurement to determine whether they are within the predetermined specifications; inserting a first edge of the gauge between the side flap and the back flap as diagonally joined into engagement with the adhesive material and reading a depth of penetration of the first edge of the gauge; inserting at least a portion of the second body of the gauge between the back flap and the side flap at the bottom fold and into engagement with the adhesive material and reading a depth of penetration of the second body; opening a diagonal seam fold of the envelope to expose the side flap on the inside of the test envelope, inserting a second edge of the gauge between the back flap and the inside edge of one of the side flaps into engagement with the adhesive material and reading a depth of penetration of the second edge of the gauge; and inserting a third edge of the gauge between the back flap and the side flap at a top end of the diagonal seam and reading a depth of penetration of the third edge of the gauge.
17. The method of Claim 16, further comprising: establishing a plurality of controllable manufacturing parameters; and adjusting one or more of the manufacturing parameters to correct for any out of specification readings.
18. The method of Claim 16, further comprising: laying a transparent portion of the gauge over the diagonal seam of the test envelope and determining if the diagonal seam is approximately a same width as the transparent portion of the gauge.
19. A method of manufacturing a measuring gauge for determining whether envelopes meet predetermined specifications, the method comprising: providing a first body; providing a second body protruding from the first body; locating a first indicia along a side of the first body for indicating an in or out of specification of a first portion of an envelope; locating a second indicia on the second body for indicating an in or out of specification for a second portion of an envelope; and locating a third indicia on a side of the first body opposite from the first indicia for indicating an in or out of specification for a third portion of an envelope.
20. The method of claim 19, further comprising: arranging a transparent section located lengthwise between the first indicia and the third indicia for indicating an in or out of specification for a fourth portion of an envelope.
21. A method of testing diagonal seam envelopes in a production line, each of the envelopes having a back flap and a front flap joined at a bottom fold, and first and second side flaps joined to said back flap at first and second side folds such that they form a diagonal seam in relation to the body of the envelope, an adhesive material securing the back flap to the first and second side flaps and utilizing a measuring gauge having a first body and a second body protruding from the first body, the measuring gauge having indicia disposed along side edges thereof that may be read by a user to ascertain whether a portion of an envelope is within predetermined specifications, the method comprising: inserting a first edge of the gauge between the side flap and the back flap as diagonally joined into engagement with the adhesive material and reading a depth of penetration of the first edge of the gauge; inserting at least a portion of the second body of the gauge between the back flap and the side flap at the bottom fold and into engagement with the adhesive material and reading a depth of penetration of the second body; opening a diagonal seam fold of the envelope to expose the side flap on the inside of the test envelope, inserting a second edge of the gauge between the back flap and the inside edge of one of the side flaps into engagement with the adhesive material and reading a depth of penetration of the second edge of the gauge; inserting a third edge of the gauge between the back flap and the side flap at a top end of the diagonal seam and reading a depth of penetration of the third edge of the gauge; and laying a transparent portion of the gauge over the diagonal seam of the test envelope and determining if the diagonal seam is approximately a same width as the transparent portion of the gauge.
22. A measuring gauge for determining whether envelopes meet predetermined specifications, the measuring gauge comprising: a first body; a second body protruding from the first body; a first indicia located along a side of the first body for indicating an in or out of specification of a first portion of an envelope; a second indicia located on the second body for indicating an in or out of specification for a second portion of an envelope; a third indicia located on a side of the first body opposite from the first indicia for indicating an in or out of specification for a third portion of an envelope; and a transparent section located lengthwise between the first indicia and the third indicia for indicating an in or out of specification for a fourth portion of an envelope; wherein each indicia are comprised of at least two different bands representing different in or out specifications for a respective portion of the envelope.
23. A measuring gauge for determining whether envelopes meet predetermined specifications, the measuring gauge comprising: a rectangular body having an angular protrusion at right angles to the rectangular body; a first indicia located along a side of the rectangular body for indicating an in or out of specification of a first portion of an envelope; a second indicia located on the angular protrusion for indicating an in or out of specification for a second portion of an envelope; a third indicia located on a side of the rectangular body opposite from the first indicia for indicating an in or out of specification for a third portion of an envelope; and a transparent section located lengthwise between the first indicia and the third indicia for indicating an in or out of specification for a fourth portion of an envelope. |
SEAM ENVELOPE GAUGE SYSTEMS AND METHODS
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application 60/959,407, filed 7/13/2007, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to the manufacture of envelopes on a production line manufacturing apparatus and more particularly to a system and method for detecting presence of gum at predetermined positions of an envelope in the production line.
[0003] Envelope manufacturing machines which fold the closure, side, and bottom flaps or panels of envelope blanks are well known in the prior art. In addition, machines for manufacturing envelopes on a production line basis are also well known, including machines that automatically apply gum adhesive to predetermined portions of the envelope blank during the manufacturing process.
[0004] While it is known to make envelopes and apply gum adhesives to various flaps and other portions of the envelope in a continuous production line system, if the gum adhesive is incorrectly applied to the predetermined areas of the envelope, then the envelope will not function as designed. This will in turn negatively affect the basic use of the envelope as well as cause problems with inserting equipment and postal sorting equipment. Traditional ways to validate the correct positioning of gum adhesive at predetermined points on the envelope blank have included visual inspection, holding the envelope to a template, manually measuring portions of the envelope, and the like. Such methods rely on an interpretation of a measurement apparatus as well as various standards and specifications. Additionally, these methods require a multiplicity of tools, are time consuming, and subject to error.
[0005] Apparatus and Method for Determining Whether an Envelope is in or out of Specification, Application No. 11/760,999, filed June 11, 2007, discloses using a gauge including multiple elements of measurement and indicia to determine whether gum positions on an envelope are present and positioned correctly. However, this invention
applies specifically to envelopes manufactured in a side seam style (also called twin seam, booklet, or double side seam envelopes).
SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention may be directed to a measuring gauge for determining that a diagonal seam gum application and a position of the gum application on diagonal seam envelopes meet predetermined specifications as well as a method of manufacturing envelopes in production lines utilizing the measuring gauge. [0007] A measuring gauge for determining whether envelopes meet predetermined specifications in accordance with an embodiment of the present invention may include, but is not limited to, a first body, a second body, a first indicia, a second indicia, and a third indicia. The second body may protrude from the first body. The first indicia may be located along a side of the first body for indicating an in or out of specification of a first portion of an envelope. The second indicia may be located on the second body for indicating an in or out of specification for a second portion of an envelope. The third indicia may be located on a side of the first body opposite from the first indicia for indicating an in or out of specification for a third portion of an envelope. [0008] A method of manufacturing diagonal seam envelopes in a production line, each of the envelopes having a back flap and a front flap joined at a bottom fold, and first and second side flaps joined to said back flap at first and second side folds such that they form a diagonal seam in relation to the body of the envelope, an adhesive material securing the back flap to the first and second side flaps and utilizing a measuring gauge having a first body and a second body protruding from the first body, the measuring gauge having indicia disposed along side edges thereof that may be read by a user to ascertain whether a portion of an envelope is within predetermined specifications, in accordance with an embodiment of the present invention may include, but is not limited to, (i) selecting at least one test envelope during a production run for measurement to determine whether they are within the predetermined specifications, (ii) inserting a first edge of the gauge between the side flap and the back flap as diagonally joined into engagement with the adhesive material and reading a depth of penetration of the first edge of the gauge, (iii) inserting at least a portion of the second body of the gauge
between the back flap and the side flap at the bottom fold and into engagement with the adhesive material and reading a depth of penetration of the second body, (iv) opening a diagonal seam fold of the envelope to expose the side flap on the inside of the test envelope, inserting a second edge of the gauge between the back flap and the inside edge of one of the side flaps into engagement with the adhesive material and reading a depth of penetration of the second edge of the gauge, and (v) inserting a third edge of the gauge between the back flap and the side flap at a top end of the diagonal seam and reading a depth of penetration of the third edge of the gauge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 illustrates a gauge according to an embodiment of the present invention;
[0010] Figure 2 illustrates a diagram of an envelope blank for use with the gauge according to an embodiment of the present invention;
[0011] Figure 3 illustrates a diagram of the envelope blank showing side flaps of the envelope blank folded;
[0012] Figure 4 illustrates a diagram of the envelope blank showing the side flaps and a back flap of the envelope blank folded to form a folded envelope;
[0013] Figure 5 illustrates a diagram of the folded envelope with the gauge inserted to measure a bottom gum position according to an embodiment of the present invention;
[0014] Figure 6 illustrates a diagram of the folded envelope with the gauge inserted to measure a top gum position according to an embodiment of the present invention;
[0015] Figure 7 illustrates a diagram of the folded envelope with the gauge inserted to measure an outside diagonal seam gum position according to an embodiment of the present invention;
[0016] Figure 8 illustrates a diagram of the folded envelope with the gauge placed over a flap of the folded envelope to measure an overlap of the flap according to an embodiment of the present invention;
[0017] Figure 9 illustrates a diagram of an open envelope with the gauge inserted to measure an inside diagonal seam gum position according to an embodiment of the present invention; and
[0018] Figure 10 illustrates a matrix for use with the gauge according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] According to an embodiment of the present invention, a measuring gauge may comprise a flat, transparent device containing multiple band widths and colors for the purpose of measuring gum line placement and position at a plurality of areas of a diagonal seam envelope. In some embodiments, in two sections of the measuring gauge, a green bar may be sandwiched between a red bar and a blue bar. A third section of the measuring gauge may include a green bar and a blue bar. A fourth section of the measuring gauge may be left transparent, the effect of which may form a window of precise height along the long axis of the gauge.
[0020] When any measurement of a diagonal seam gum line position falls within the green bar section of the gauge, gum line placement may be acceptable based on predetermined specifications. When any measurement of the diagonal seam gum line position falls within either the red or blue bar sections of the gauge, the diagonal seam gum line position may not meet the predetermined specifications and various actions may be taken to bring the diagonal seam gum line placement within the predetermined specifications.
[0021] When measurements of an overlap of the side flap and the back flap along the diagonal seam of the envelope extend past the transparent section of the gauge the diagonal seam gum line position may not meet the predetermined specification and various actions may be taken to bring the diagonal seam gum line placement into the predetermined specifications.
[0022] Fig. 1 illustrates a gauge 5 according to an embodiment of the present invention. The gauge 5 may include, but is not limited to, a first body 10 and second body 16. The first body 10 may have a first end edge 12, a second end edge 14, an upper edge 26, and a lower edge 34. In some embodiments, the first body 10 may have a rectangular or square cross-section. Accordingly, the first end edge 12 and the second end edge 14 may be parallel to each other, and the upper edge 26 and the lower edge 34 may be parallel to each other.
[0023] The first body 10 and/or the second body 16 may be formed of a thin, flexible material, such as Mylar, plastic, or any suitable translucent material, or the like, to allow portions of the first body 10 and/or the second body 16 to be inserted between flaps of an envelope as discussed later. For example, the gauge 5 may have a thickness between .001" and .007" thick (1-7 mils). However, any thickness may be employed that allows portions of the first body 10 and/or the second body 16 to be inserted between the flaps of the envelope without destroying the gum lines or the flaps. In other embodiments, the first body 10 and/or the second body 16 may be formed of a cutout metal material, or the like. In various embodiments, the first body 10 may further include a transparent portion.
[0024] The second body 16 may extend from one of the first end edge 12 and the second end edge 14 of the first body 10. In some embodiments, the second body 16 may extend from the first body 10 at an angle. In further embodiments, the second body 16 may be a triangular segment 16 that may extend from approximately a center point of one of the first end edge 12 and the second end edge 14 of the body 10 and may extend downwardly so that a hypotenuse 17 of the triangular segment 16 terminates at a point aligned with the lower edge 34 of the first body 10. The triangular segment 16 may be at a right angle to the first body 10, as shown in Fig. 1.
[0025] In various embodiments, the second body 16 (or triangular segment) may extend from the first body 10 at any suitable angle. In such embodiments, a length of the second body 16 may change in accordance with the angle at which the second body 16 extends from the first body 10. For example, using a larger angle, will allow for a narrower second body 16.
[0026] The triangular segment 16 may include a first portion 20, a second portion 22, and a third portion 24. Each of the portions 20, 22, and 24 may be parallel to each other and arranged such that the second portion 22 is sandwiched between the first portion 20 and the third portion 24. In some embodiments, each of the portions 20, 22, and 24 may be of varying colors, shadings, patterns, and/or contrasts. For example, the first portion 20 may be red, the second portion 22 may be green, and the third portion 24 may be blue. [0027] Although red, green, and blue are used in this exemplary embodiment, it is to be understood that any combination of colors, shadings, patterns, and/or contrasts may be
used to differentiate the first portion 20, the second portion 22, and the third portion 24. In some embodiments, the first portion 20 and the third portion 24 may be of the same color, shading, pattern, and/or contrast, while the second portion 22 may have a different color, shading, pattern, and/or contrast. For example, the first portion 20 and the third portion 24 may be opaque, and the second portion 22 may be clear. In some embodiments, the colors, shadings, patterns, and/or contrasts may be selected to allow the colors, shadings, patterns, and/or contrasts to be visible through a portion of an envelope being tested.
[0028] Each of the portions 20, 22, and 24 may have a desired thickness. In some embodiments, the desired thickness may sufficiently allow for a particular margin of error, such as +/- 1/16". For example, the first portion 20 may be 7/8" thick, while the second portion 22 may be 1/4" thick, and the third portion 24 may be 3/8" thick. Accordingly, each of the measurements of the portions 20, 22, and 24 may correspond to a perpendicular height as described by the angle of the protrusion of the second body 16 relative to the first body 10. For example, the first portion 20, which may be 7/8" thick, may correspond to a measurement in a perpendicular direction (i.e., a height of the first portion 20), such as a height of up to approximately 1/2". Meanwhile, the second portion 22, which may be 1/4" thick, may have a height ranging approximately from 1/2" to 5/8", and the third portion 24, which may be 3/8" thick, may have a height ranging approximately from 5/8" to 3/4".
[0029] In further embodiments, text (not shown) may be provided on the triangular segment 16, for example on one or more of the portions 20, 22, and 24, indicating a position of an envelope to be measured by the gauge 5. For example, the text (not shown) may read "Bottom," "Bottom Portion," "Lower Portion," or the like. [0030] In some embodiments, the first body 10 may include a first upper portion 30, a second upper portion 28, and a third upper portion 32 located near the upper edge 26 of the first body 10. The second upper portion 28 may be sandwiched between the first upper portion 30 and the third upper portion 32. In further embodiments, one or all of the upper portions 30, 28, and 32 may be parallel to the upper edge 26. In yet further embodiments, an edge of one of the upper portions 30, 28, and 32 may share or overlap the upper edge 26 of the first body 10. As discussed with respect to the portions 20, 22,
and 24 of the triangular segment 16, the upper portions 30, 28, and 32 may be of varying colors, shadings, patterns, and/or contrasts. For example, the first upper portion 30 may be red, the second upper portion 28 may be green, and the third upper portion 32 may be blue.
[0031] Although red, green, and blue are used in this exemplary embodiment, it is to be understood that any combination of colors, shadings, patterns, and/or contrasts may be used to differentiate the first upper portion 30, the second upper portion 28, and the third upper portion 32. In some embodiments, the first upper portion 30 and the third upper portion 32 may be of the same color, shading, pattern, and/or contrast, while the second upper portion 28 may have a different color, shading, pattern, and/or contrast. For example, the first upper portion 30 and the third upper portion 32 may be opaque, and the second upper portion 28 may be clear. In some embodiments, the colors, shadings, patterns, and/or contrasts may be selected to allow the colors, shadings, patterns, and/or contrasts to be visible through a portion of the envelope being tested. [0032] Each of the upper portions 30, 28, and 32 may have a desired thickness. In some embodiments, the desired thickness may sufficiently allow for a particular margin of error, such as +/- 1/16". For example, the first upper portion 30 may be 3/32" thick, while the second upper portion 28 may be 3/16" thick, and the third upper portion 32 may be 5/16" thick. In other embodiments, any thickness may be employed for the upper portions 30, 28, and 32, so long as each of the upper portions 30, 28, and 32 accounts for a target gum line thickness and tolerances for each measurement. [0033] In further embodiments, text 31 may be provided on the first body 10, for example on one or more of the upper portions 30, 28, and 32, indicating a position of an envelope to be measured by the gauge 5. For example, the text 31 may read "Top," "Top Portion," "Upper Portion," or the like.
[0034] In some embodiments, the first body 10 may include a first lower portion 38 and a second lower portion 36 located near the lower edge 34 of the first body 10. In some embodiments, one or both of the lower portions 38 and 36 may be parallel to the lower edge 34. In yet further embodiments, an edge of one of the lower portions 38 and 36 may share or overlap the lower edge 34 of the first body 10. As discussed with respect to the portions 20, 22, and 24 of the triangular segment 16 and the upper portions
30, 28, and 32, the lower portions 38 and 36 may be of varying colors, shadings, patterns, and/or contrasts. For example, the first lower portion 38 may be red and the second lower portion 26 may be green. In further embodiments, the first body 10 may include a third lower portion (not shown) similar to the third portions (24 and 32) as described above, for example a blue third lower portion.
[0035] Although red and green are used in this exemplary embodiment, it is to be understood that any combination of colors, shadings, patterns, and/or contrasts may be used to differentiate the first lower portion 38 and the second lower portion 36. In other embodiments, a clear and opaque designation may be utilized to differentiate the first lower portion 38 and the second lower portion 36. In some embodiments, the colors, shadings, patterns, and/or contrasts may be selected to allow the colors, shadings, patterns, and/or contrasts to be visible through a portion of the envelope being tested. [0036] Each of the lower portions 38 and 36 may have a desired thickness. In some embodiments, the desired thickness may sufficiently allow for a particular margin of error, such as +/- 1/16". For example, the first lower portion 38 may be 3/32" thick, while the second lower portion 36 may be 3/8" thick. In other embodiments, any thickness may be employed for the lower portions 38 and 36, so long as each of the lower portions 38 and 36 accounts for a target gum line thickness and tolerances for each measurement.
[0037] In further embodiments, text 37 may be provided on the first body 10, for example on one or more of the lower portions 36 and 38, indicating a position of an envelope to be measured by the gauge 5. For example, the text 37 may read "Inside/Outside," "Inside," "Outside," "Inner/Outer Portion," or the like. [0038] The colors, shadings, patterns, and/or contrasts of each respective region of the gauge 5 (e.g., the portions of the triangular segment 16, the upper portions of the first body 10, and the lower portions of the first body 10) may be coordinated with one or more of the other regions of the gauge 5, or none at all. For example, the portions of the triangular segment 16 may use a red, green, and blue scheme while the other portions may use a opaque, clear, opaque scheme.
[0039] Figs. 2-9 illustrate an envelope blank 45 for use with the gauge 5 according to an embodiment of the present invention. The envelope blank 45 may include a front
panel 40, a back panel 42, a side flap 44, and a side flap 46. The envelope blank 45 may further include a closing flap 48 having a gum line 50 along an edge of the closing flap 48.
[0040] With reference to Fig. 3, gum lines 54 and 52 may be applied along an edge of a backside of the side flaps 44 and 46. Next, the side flaps 44 and 46 may be folded inwardly (shown as dotted lines). The back panel 42 may be then folded upwardly to seal or otherwise attach the back panel 42 to the side flaps 44 and 46 by the gum lines 54 and 52 as shown in Fig. 4 to form a folded envelope 45'. The folded envelope 45' shown in Figs. 4-8 may be known as a diagonal seam envelope.
[0041] The gauge 5 (refer to Fig. 1) may be then utilized to measure a position of the gum lines 54 and 52 to determine whether or not the folded envelope 45' is inside or outside specifications.
[0042] With reference to Fig. 5, the gauge 5 may be used to measure the position of each of the gum lines 54 and 52 at a bottom portion of the gum lines 54 and 52. The gauge 5 may be positioned at a first measurement position alongside the folded envelope 45' to allow the hypotenuse 17 of the triangular segment 16 to contact or otherwise engage one of the gum lines 54 and 52. For example, the triangular segment 16 may be inserted into a bottom portion of the folded envelope 45' between the back flap 42 and the side flap 44 until the triangular segment 16 contacts or otherwise engages the gum line 54. Accordingly, when the gauge 5 is at the first measurement position, a portion of the gum line 54 may extend to the triangular segment 16. As such, a left edge 42b of the back flap 42 may extend over a portion of the triangular segment 16. [0043] If the left edge 42b of the back flap 42 extends to or otherwise ends within the second portion 22 (e.g., the green portion) of the triangular segment 16, the folded envelope 45' may be within a desired specification with respect to the bottom portion of the gum line 54. Accordingly, the other gum line 52 may be then measured in similar fashion. On the other hand, if the left edge 42b of the back flap 42 extends to or otherwise ends within the first portion 20 or the third portion 24 (e.g., the red portion or the blue portion, respectively), then the folded envelope 45 ' may be outside the desired specification.
[0044] With reference to Fig. 6, the gauge 5 may be used to measure the position of each of the gum lines 54 and 52 at a top portion of the gum lines 54 and 52. The gauge 5 may be positioned at a second measurement position to allow the upper edge 26 of the first body 10 to contact or otherwise engage the gum lines 54 and 42. For example, the upper edge 26 of the first body 10 may be inserted into a top portion of the folded envelope 45' between the back flap 42 and the side flaps 44 and 46 until the upper edge 26 contacts or otherwise engages the gum lines 54 and 52. As such, a top edge 42d (refer to Fig. 5) of the back flap 42 may overlap or extend over a portion of the first body 10 depending on whether the gum lines 54 and 52 are in or out of a desired specification. [0045] If the top edge 42d (refer to Fig. 5) of the back flap 42 of the folded envelope 45' extends to or otherwise falls within the second upper portion 28 (e.g., the green portion) then the folded envelope 45 ' may be within the desired specification with respect to the top portion of the gum lines 54 and 52. On the other hand, if the top edge 42d (refer to Fig. 5) of the back flap 42 extends to or otherwise falls within the first upper portion 30 or the third upper portion 32 (e.g., the red portion or the blue portion, respectively), then the folded envelope 45' may be outside the desired specification. [0046] In various embodiments, placement of the gauge 5 to measure the position of each of the gum lines 54 and 52 at the top portion of the gum lines 54 and 52, may allow a user to visibly note variations between the left gum line 54 and the right gum line 52 from the top edge 42d (refer to Fig. 5) of the back flap 42. For example, if the top edge 42d (refer to Fig. 5) of the back flap 42 of the folded envelope 45' extends to or otherwise falls within the second upper portion 28 (e.g., the green portion), then the gum lines 54 and 52 may be level with each other. However, if the gauge 5 is visibly slanted when performing the measurement, then the folded envelope 45' may be outside the desired specification. Uneven gum lines can lead to inserter machine jams, excess down time of the machines, and customer rejection of the envelopes.
[0047] With reference to Fig. 7, the gauge 5 may be used to measure a position of each of the gum lines 54 and 52 along an outer portion of the gum lines 54 and 52. The gauge 5 may be positioned at a third measurement position to allow the lower edge 34 of the first body 10 to contact or otherwise engage one of the gum lines 54 and 52. For example, the lower edge 34 of the first body 10 may be inserted between the back flap 42
and the side flap 44 until the lower edge 34 contacts or otherwise engages the gum line 54. As such a left edge 42b (refer to Fig. 5) of the back flap 42 may overlap or extend over a portion of the first body 10 depending on whether the gum line 54 is in or out of a desired specification.
[0048] If the left edge 42b (refer to Fig. 5) of the back flap 42 of the folded envelope 45' extends to or otherwise falls within the second lower portion 36 (e.g., the green portion) then the folded envelope 45 ' may be within the desired specification with respect to the outer portion of the gum line 54. Accordingly, the other gum line 52 may be then measured in similar fashion. On the other hand, if the left edge 42b (refer to Fig. 5) of the back flap 42 of the folded envelope 45' extends to or otherwise falls within the first lower portion 36 (e.g., the red portion), then the folded envelope 45' may be outside the desired specification.
[0049] With reference to Fig. 8, in some embodiments, the first body 10 may include a transparent portion 25 arranged between the upper portions (e.g., the third upper portion 32) and the lower portions (e.g., the second lower portion 36). The transparent portion 25 of the first body 10 may be parallel to the upper portions and the lower portions of the first body 10. In some embodiments, the transparent portion 25 of the first body 10 may have a desired thickness. The desired thickness may sufficiently allow for a particular margin of error, such as +/- 1/16". For example, the transparent portion 25 of the first body 10 may be 7/16" thick.
[0050] The gauge 5 may be placed at a fourth measurement position over the folded envelope 45' to measure an overlap of the back flap 42 and each of the side flaps 44 and 46 with the transparent portion 25 of the gauge 5. An area or border between the transparent portion 25 and either of the third upper portion 32 or the second lower portion 36, for example, may be aligned with either of the left edge 42b (refer to Fig. 5) of the back flap 42 or the left edge 44b (refer to Fig. 5) of the side flap 44. [0051] For example, in the embodiment illustrated in Fig. 8, a line between the third upper portion 32 and the transparent portion 25 may be aligned with the left edge 12b (refer to Fig. 5) of the back flap 42. If the left edge 42b (refer to Fig. 5) of the side flap 42 at least extends the entire width of the transparent portion 25 (i.e., reaches the second lower portion 36) then the folded envelope 45' may be within the desired specification
with respect to the overlap of the back flap 42 and the side flap 44. Accordingly, the overlap of the back flap 42 and the side flap 46 may be then measured in similar fashion. On the other hand, if the left edge 44b (refer to Fig. 5) of the side flap 44 does not at least extend the entire width of the transparent portion 25, then the folded envelope 45' may be outside the desired specification.
[0052] In some embodiments, the overlap portion of the folded envelope 45' may extend beyond the transparent portion 25 and still be within the desired specification. In other words, the overlap portion may be wider than the transparent portion 25. In other embodiments, the folded envelope 45' may be outside the desired specification if the overlap portion of the folded envelope 45' extends beyond the transparent portion 25. [0053] In further embodiments, text (27 in Fig. 1) may be provided on the transparent portion 25 of the first body 10, indicating a position of an envelope to be measured by the gauge 5. For example, the text (27 in Fig. 1) may read "Overlap," or the like. [0054] With reference to Fig. 9, which illustrates an open envelope 45", the gauge 5 may be used to measure a position of each of the gum lines 54 and 52 along an inner portion of the gum lines 54 and 52. The folded envelope 45' may be slit or otherwise cut along side edges 44a and 46a (refer to Fig. 5) to allow the back panel 42 and the side flaps 44 and 46 to be folded down as shown in Fig. 8. The gauge 5 may be positioned at a fifth measurement position to allow the lower edge 34 of the first body 10 to contact or otherwise engage one of the gum lines 54 and 52. For example, the lower edge 34 of the first body 10 may be inserted between the folded down back flap 42 and the folded down side flap 44 until the lower edge 34 of the first body 10 contacts or otherwise engages the gum line 54. As such the left edge 44b (refer to Fig. 5) of the side flap 44 may overlap or extend over a portion of the first body 10 depending on whether the gum line 54 is in or out of a desired specification.
[0055] If the left edge 44b (refer to Fig. 5) of the side flap 44 extends to or otherwise falls within the second lower portion 36 (e.g., the green portion) then the folded envelope 45' (the open envelope 45") may be within the desired specification with respect to the outer portion of the gum line 54. Accordingly, the other gum line 52 may be then measured in similar fashion. On the other hand, if the left edge 44b (refer to Fig. 5) of the side flap 44 extends to or otherwise falls within the first lower portion 36 (e.g., the
red portion), then the folded envelope 45' (the open envelope 45") may be outside the desired specification.
[0056] With reference to Fig. 1, in some embodiments, the triangular segment 16 may comprise a blade portion (not shown), which may be for slitting or otherwise cutting along the side edges 44a and 46a (refer to Fig. 5) to allow the back panel 42 and the side flaps 44 and 46 to be folded down as shown in Fig. 9. In other embodiments, the blade portion (not shown) may be attached to any of the first body 10 edges. [0057] In some embodiments, the gauge 5, either in its entirety or its individual components (such as the first body 10 or the second body 16) may be made of a thin flexible and/or durable material to allow the triangular segment (the second body) 16 to be insertable between the back flap 42 and the side flaps 44 and 46. For example, at a position where the back flap 42 and each of the side flaps 44 and 46 meet and overlap each other.
[0058] In various embodiments, the gauge 5 parameters and/or specifications, including, but not limited to, the dimensions of the portions (e.g., 20, 22, 24), the angle of the second body 16 relative to the first body 10, the size of the first body 10 and the second body 16, may be varied depending on dimensions of envelopes being measured with the gauge 5. For example, according to an embodiment of present invention as described above, many of the gauge 5 specifications may be directed toward measuring a No. 10 envelope. Although such a gauge may be for measuring a No. 10 envelope, the gauge 5 may be for measuring specifications of other various-sized envelopes as well. Alternatively or in addition, the other various-sized envelopes may be measured with a gauge having specific parameters and/or dimensions specifically directed to one or more of these other various-sized envelopes.
[0059] In various embodiments, the different colors, shadings, patterns, and/or contrasts may be for categorizing readings of the envelope manufacturing apparatus. For example, if an envelope flap edge extends into the first upper portion 30 (e.g., the red portion), then this may indicate that at least one of the gum lines 52 and 54 may be too long. In some embodiments, the gauge 5 may be used in conjunction with a matrix 200, an example of which is illustrated in Fig. 10. With the categorized readings, an operator
of the envelope manufacturing apparatus may be able to calibrate the envelope manufacturing apparatus according to information provided by the matrix 200. [0060] In various embodiments, the gauge 5 as described above may be utilized during a manufacturing process of envelopes.
[0061] In some instances, envelopes may be manufactured in a production run utilizing automatic equipment that applies diagonal seam gum lines to desired positions on the envelopes. The envelopes may be folded and sealed in a manner shown in the drawings and described above. Application of the gum lines to various portions of the envelope may be controlled by parameters that may be programmed into computers, and the like that control manufacturing equipment used in the production line. [0062] In some embodiments, one or more test envelopes may be extracted for testing periodically from the envelopes in the production line. In further embodiments, the production line may be run a period of time to allow adherence of the gum adhesive of the gum lines of the envelopes. For example, three test envelopes may be extracted from the production line every thirty minutes for testing. The three test envelopes may be selected consecutively or at random from the production line. In yet further embodiments, test envelopes may be selected in accordance with certain events, such as at a starting of an operator shift, a machine start up (e.g., after a jam or repair), or at random intervals.
[0063] The gauge 5 may be used to determine whether or not diagonal seam gum lines are properly positioned on the test envelopes. If the gauge 5 shows that one of the gum lines is not properly positioned such that, for example, one of the flap edges of the test envelope falls within either the red or blue portions of the gauge 5, then the test envelope may be out of specification. Accordingly, the production line can be stopped and the manufacturing equipment may be reprogrammed to correct any malfunction(s) that caused the test envelope (and the other envelopes in the production line) to be out of specification. In some embodiments, the manufacturing equipment may be reprogrammed in accordance with the readings provided by the gauge 5 and/or the matrix 200 (refer to Fig. 10). Subsequently, the production line can then again be started and new test envelopes from the production run after correction of the parameters may be
extracted and tested to be sure that the new test envelopes are now currently within specification.
[0064] The embodiments disclosed herein are to be considered in all respects as illustrative, and not restrictive of the invention. The present invention is in no way limited to the embodiments described above. Various modifications and changes may be made to the embodiments without departing from the spirit and scope of the invention. The scope of the invention is indicated by the attached claims, rather than the embodiments. Various modifications and changes that come within the meaning and range of equivalency of the claims are intended to be within the scope of the invention.