Method of and apparatus for manufacturing envelopes

A method of forming envelopes from a continuous paper web and for incorporation of insert material into the envelope during their formation comprising the following steps:

• (a) intermittently advancing a paper web along a first path;
• (b) scoring said web along longitudinal and transverse lines and notching said web at spaced intervals for defining an envelope blank having a bottom flap on one side of said web, a closure flap on the opposite side of said web, and an end flap at each end thereof;
• (c) folding each of said bottom flaps during passage of said web along said first path so that it forms an acute angle with the upper surface of its respective blank to form a pocket;
• (d) stopping the advance of said web with the leading end thereof located at a predetermined position;
• (e) creating subatmospheric pressure beneath said leading envelope blank when it is in said predetermined position for holding said envelope blank in said position;
• (f) severing the leading envelope blank from said web;
• (g) charging insert material into the pocket defined by the bottom flap of said severed envelope blank;
• (h) advancing said charged envelope blank from said predetermined position along a second path in a direction which is opposite to the opening of said pocket and urging the bottom flap thereof into overlying relationship with said insert material;
• (i) applying adhesive to each of the end flaps into sealing relationship with the bottom flap of said charged envelope blank;
• (j) folding said glued end flaps into sealing relationship with the bottom flap of said charged envelope blank;
• (k) applying adhesive to the closure flap of said charged envelope blank;
• and
• (l) folding the glued closure flap of said charged envelope blank into sealing relationship with the bottom and end flaps.

In a method of forming and stuffing an insert into and sealing an envelope blanked from a paper web, the steps of:

• Intermittently advancing the web in a first advancing mode along a first linear path,
• scoring the web along preselected longitudinal and transverse lines and notching the web at preselected spaced intervals for defining the bottom and closure and end flaps of eventually-in seriatim-severed blanks during advance along the first linear path,
• forming a pocket in the leading web end by folding the bottom flap,
• bringing the web to a non-advancing mode and registering and holding the leading web end in a preselected seized position,
• severing the leading web end in a blank forming manner,
• charging the insert into the pocket,
• pressing the bottom flap into overlying relationship with the insert,
• advancing the stuffed blank in a second advancing mode away from the pressing and seizing position along a second linear path perpendicular to the first linear path,
• gluing each of the blank end flaps and folding the blank end flaps into sealing relationship with the bottom flap during advance along the second linear path,
• terminating the advance of the blank along the second linear path,
• advancing the blank in a third advancing mode along a third linear path perpendicular to the second linear path,
• gluing the blank closure flap during advance along the third linear path,
• folding the blank closure flap into sealed relationship with the bottom and end flaps during advance along the third linear path, and
• discharging the fully loaded and sealed blank at the terminus of the third linear path.

A machine for forming envelopes from a continuous paper web and for incorporation of insert material into the envelopes during their formation comprising:

• (a) means for intermittently advancing along a first path a paper web comprising defined envelope blanks having a bottom flap on one side of said web, a closure flap on the opposite side of said web and an end flap at each end thereof;
• (b) primary flap folding means for partially folding each of said bottom flaps to form a pocket having an acute angle during advance of said web;
• (c) means for stopping the advance of said web with the leading end thereof at a predetermined position;
• (d) means for severing the leading envelope blank from the web while said closure and end flaps remain in the same plane as said web;
• (e) means for charging insert material into the pocket defined by the bottom flap of said severed envelope blank;
• (f) means for restraining a leading envelope blank during charging of insert material into the pocket defined by the bottom flap of said envelope blank;
• (g) a backup plate which abuts the pocket defined by the bottom flap of said leading envelope blank during charging of insert material into said pocket;
• (h) means for urging the bottom flap of said charged envelope blank into overlying relationship with the inserted material;
• (i) means for advancing said charged envelope blank from said predetermined position along a second path which is perpendicular to said first path in a direction which is opposite to the opening of said pocket;
• and
• means for applying adhesive material to the end flaps and closure flap of said charged envelope and folding said end and closure flaps into sealing relationship to form a completed charged envelope.

A machine for forming envelopes from a continuous paper web and for incorporation of insert material into the envelopes during their formation comprising:

• (a) means for intermittently advancing a paper web along a first path;
• (b) means for scoring said web along longitudinal and transverse lines and notching said web at spaced intervals for defining an envelope blank having a bottom flap on one side of said web, a closure flap on the opposite side of said web, and an end flap at each end thereof;
• (c) primary flap folding means for partially folding each of said bottom flaps during passage of said web along said first path so that it forms an acute angle with the upper surface of its respective blank to form a pocket;
• (d) means for stopping the advance of said web with the leading end thereof located at a predetermined position;
• (e) means for creating subatmospheric pressure beneath said leading envelope blank when it is in said predetermined position for holding said envelope blank in said position;
• (f) means for severing the leading envelope blank from said web;
• (g) means for charging insert material into the pocket defined by the bottom flap of said severed envelope blank;
• (h) means for advancing said charged envelope blank from said predetermined position along a second path which is perpendicular to said first path in a direction which is opposite to the opening of said pocket and urging the bottom flap thereof into overlying relationship with said insert material;
• (i) means for applying adhesive to each of the end flaps of said charged envelope blank;
• (j) means for folding said glued end flaps into sealing relationship with the bottom flap of said charged envelope blank;
• (k) means for applying adhesive to the closure flap of said charged envelope blank;
• and
• (l) means for folding the glued closure flap of said charged envelope blank into sealing relationship with the bottom and end flaps.

A machine for forming envelopes from a continuous paper web and for incorporation of insert material into the envelopes during their formation comprising:

• (a) means for intermittently advancing a paper web along a first path;
• (b) means for scoring said web along longitudinal and transverse lines and notching said web at spaced intervals for defining an envelope blank having a bottom flap on one side of said web, a closure flap on the opposite side of said web, and an end flap at each end thereof;
• (c) primary flap folding means for partially folding each of said bottom flaps to form a pocket during passage of said web along said first path;
• (d) means for stopping the advance of said web with the leading envelope blank thereof located at a predetermined position;
• (e) means for severing the leading envelope blank from said web;
• (f) means for charging insert material into the pocket defined by the bottom flap of said severed envelope blank;
• (g) means for urging the bottom flap of said charged envelope blank into overlying relationship with the inserted material;
• means for advancing said charged envelope blank along a second path which is perpendicular to said first path in a direction which is opposite to the opening of said pocket;
• (i) means for applying adhesive to each of the end flaps of said charged envelope blank during passage of said charged envelope along said second path;
• (j) means for folding said glued end flaps into sealing relationship with the bottom flap of said charged envelope blank during passage thereof along said second path;
• (k) means for advancing said charged envelope along a third path which is perpendicular to said second path;
• (l) means for applying adhesive to the closure flap of said charged envelope;
• and
• (m) means for folding the closure flap of said charged envelope into sealing relationship with the bottom and end flaps during passage along said third linear path.