Technical Field of the Invention

The present invention relates to a continuous web which is separated into discrete base sheets and folded to form two-way mailers having return mailers, and in particular to a spirally-wrapped two-way mailer with an integral return mailer that is simple and efficient to produce while also being suitable for postal service automation discount requirements.

Background of the Invention

Continuous webs which can be separated into discrete base sheets and folded to form two-way mailers with return envelopes or the like are well known in the art. Such mailers fail, however, to efficiently provide for printing information onto the base sheet or be easy to produce on a continuous basis.

For example, Bendel U.S. Pat. No. 5,125,562 depicts a rectangular base sheet which requires gluing on both sides to form a two-way mailer. The mailer base sheet is divided into multiple adjoining panels by equally spaced traverse fold lines. Applied to one side of the base sheet are longitudinal bands of glue which extend along the marginal edges of the base sheet. Disposed on the other side of the base sheet are traverse glue bands which are disposed generally parallel and proximate to every-other fold line. The base sheet is formed into a two-way mailer with an outgoing return envelope by folding the base sheet along the traverse fold lines in a "fan fold" arrangement such that each panel overlies onto an adjoining panel. The longitudinal and traverse glue bands on both sides of the base sheet secure the panels to each other in order to hold the two-way mailer together during mailing.

The need for glue bands on both sides of the base sheet renders production of the mailer difficult and expensive. Equipment must be provided which is capable of applying glue to both sides and in strips which longitudinally and traversely across the base sheet.

Further, the need for glue bands along the traverse fold lines for attaching every-other panel together severely limits where and how information can be printed on the panels of the two-way mailer.

Information cannot be printed where glue is applied to the base sheet because the glue will cover or mar the ink print. Thus, full or continuous ink coverage is not possible between all of the base sheet panels because of the gaps generated by those glue bands which traverse across the base sheet.

Further, if color printed information is desired, then tight registration is needed between each panel in order to ensure that each individual color is positioned correctly. However, the gaps cause by the traverse glue bands results in tight registration being a difficult and time consuming task.

Perforations which traverse across the base sheet also result in the need for gaps in printing information. For example, ise et al. U.S. Pat. No. 3,977,597 has three traverse lines of perforations at parallel positions for dividing the base sheet into four severable panels. Placing information over the perforation lines can result in the print becoming blurred or disfigured. Thus, gaps are usually required when printing information from one panel to the next.

Many two-way mailers made of a continuous web are also confusing and difficult for the addressee to correctly disassembly without accidently tearing or destroying the return envelope or the printed information inside. For example, many mailers have

multiple instructions at various locations which detail the required sequence of steps for the recipient to open the mailer. As a result of having to follow such complex instructions, many recipients throw the mailers away instead of attempting to open them.

Besides failing to provide a simple and efficient construction, many two-way mailers constructed from a single base sheet also fail to comply with current postal requirements for automated processing. In an effort to quickly process the mail, automated processing equipment is used that requires each piece of mail to conform to certain dimensional and construction constraints. For mailers made from a single base sheet, it is desirable that only one sealed flap or open edge be provided which extends along the top side of the mailer. The bottom and side portions of the mailer must be closed or sealed. Failure to satisfy this requirement will result in paying more in postage to have the mailer delivered. Accordingly, what is needed is a two-way mailer with a return envelope or postcard which is simple and efficient to produce. The mailer should also be constructed such that it is suitable for processing by automated postal sorting equipment. The present invention meets these desires.

Summary of the Invention

The present invention is a two-way mailer having a simple and efficient construction. The mailer embodying the present invention is especially suitable for use in correspondence requiring a return envelope or postcard. The mailer is constructed from a rectangular base sheet which has glue applied to only one side of the sheet. The efficient design of the mailer allows for practically full ink-coverage on both sides of the

base sheet. In addition, the mailer is compatible for use by automated postal sorting equipment.

The two-way mailer embodying the present invention includes a rectangular base sheet having a front face, a rear face, and two parallel marginal edges. Proximate to the marginal edges are two parallel lines of weakening. The base sheet is divided into a plurality of adjoining panels by generally parallel fold lines traversing the base sheet such that there is a front panel, a back panel, and at least one intermediate panel between the front panel and the back panel. A return mailer is provided by attaching the rear face of the back panel to the rear face of an adjoining intermediate panel with two parallel adhesive lines on the rear face disposed interior of and proximate to the lines of weakening. Substantially parallel glue lines are disposed on the rear face within portions adjacent to both the tear lines and the marginal edges for securing the panels together to form an out-going two- way mailer with an integral return mailer.

Brief Description of the Drawings

FIGURE 1 is a fragmentary plan view of an embodiment of the present invention illustrating a connected series of base sheets within a continuous web;

FIGURE 2 is a fragmentary rear plan view of the connected series of base sheets illustrated in FIGURE 1;

FIGURE 3 is a perspective ievelopment view of one of the base sheets illustrated i. FIGURE 1 being formed into a two-way mailer with an integral return mailer;

FIGURE 4 is a perspective development view similar to FIGURE 3, but with the base sheet being in a further stage of formation into a two-way mailer;

FIGURE 5 is a fragmentary perspective view of the base sheet of FIGURE 4 formed into a two-way mailer in accordance with the present invention;

FIGURE 6 is a perspective view of a return envelope separated from the two-way mailer of FIGURE 5;

FIGURE 7 is a plan view of another embodiment of a base sheet for forming a two-way mailer in accordance with the teachings of the present invention; and FIGURE 8 is a rear plan view of the base sheet illustrated in FIGURE 7.

Detailed Description of the Preferred Embodiments The present invention provides a two-way mailer having a simple and efficient construction. The two-way mailer embodying the present invention includes a rectangular base sheet having a front face, a rear face, and two parallel marginal edges. Proximate to the marginal edges are two substantially parallel lines of weakening. The base sheet is divided into a plurality of adjoining panels by parallel fold lines traversing the base sheet such that there is a front panel, a back panel, and one or more intermediate panels between the front panel and the back panel. Two generally parallel adhesive lines on the rear face disposed interior of and proximate to the lines of weakening attach the rear face of the back panel to the rear face of an adjoining intermediate panel to form a return mailer. Further, the remaining panels are secured together by two glue lines on the rear face adjacent to both the marginal edges and the lines of weakening.

Referring to the drawings, and particularly to FIGURES 1 and 2, a fragmentary front and rear plan view is provided of a continuous web 10 comprising a single ply of paper. The continuous web 10 is separable into elongated rectangular base sheets 12 which are joined

one to the other at opposite ends by laterally extending separation lines 14 which may consist of perforations or the like. As described in detail further herein, each base sheet 12 is used to form a discrete two-way mailer. The continuous web 10 includes a plurality of sprocket openings 16 which form two generally parallel tractor feed lines 18 and 19 that longitudinally extend proximate to web marginal edges 20 and 21, respectively. The openings 16 within each tractor feed line 18,19 are generally equally spaced one from the other and provide for the processing of the continuous web 10 by machines, such as high-speed printers (not shown) , having correspondingly spaced tractor drive sprocket pins. Correspondingly, the web 10 may be disposed within various machines common in the industry for slitting, perforating, printing, and adhesive applying operations on various portions of the web as described below.

Further, disposed proximate to the marginal edges 20,21 of the web 10 and interior of lines 18 and 19 are two tear lines 22 formed by perforations. The tear lines 22 are generally parallel to each other and the tractor feed lines 18,19. The tear lines 22 define two opposing removable drive tabs 24 and 25 that include tractor feed lines 18 and 19, respectively. The tear lines 22 provide for removing the drive tabs 24,25 once printing and assembly of the mailer is completed as described below.

Although it is preferred that the base sheet 12 be provided with removable drive tabs 24,25 with openings 16 for processing the base sheet by using a tractor drive, it will be appreciated by those skilled in the art that these elements are not necessarily required. Instead, the base sheet 12 can be processed by using rollers for moving the base sheet though various machines for printing and performing other such operations.

Disposed proximate to the marginal edges 20,21 and interior of the two tear lines 22 are two lines of weakening 26 and 27 that extend longitudinally along the drive tabs 24 and 25, respectively. The lines of weakening 26,27 are generally parallel to the tear lines 22 and are separated from each other by a predetermined distance to provide side strips 28 and 29, respectively, therebetween.

The lines of weakening 26,27 may be formed by perforations or the like and provide for opening the mailer as described further herein. Preferably, the lines of weakening 26,27 do not tear as easy as tear lines 22 such that, when the drive tabs 24,25 are subject to a strain which pulls them away from each other, the drive tabs will separate from the base sheet 12 without detaching the side strips 28,29 from the base sheet.

As illustrated in FIGURES 1 and 2, the front face 30 and the rear face 32 of the base sheet 12 is divided into a plurality of adjoining panels 33 including a front panel 34, an back panel 36, and at least one intermediate panel 38 between the front panel and the back panel. Although three intermediate panels 38 are illustrated in FIGURES 1 and 2, the invention described herein entails any number of intermediate panels so long as at least one intermediate panel is provided.

The back panel 34 of the base sheet 12 has a traverse tear line 40 disposed generally parallel with line 14 and separated from each other by a predetermined distance to provide removable strip 42. The tear line 40 may be formed by a plurality of perforations or the like and provides for detaching removable strip 42 from the base sheet 12 which, as described below, allows for sealing a return envelop by using a flap.

The division between panels 33 is demarcated by traverse fold lines 44 which are spaced-apart and parallel to each other. Preferably, the traverse fold lines 44 are equally spaced one from the other such that all panels 33 are of generally equal size. However, it is not necessary for all panels 33 to be of substantially similar size. Instead, only the front panel 34 and its adjoining panel 45 must have generally the same size relative to each other and be equal or larger in size to the rest of the panels such that panels 34 and 45 can receive the other panels as described below.

The fold lines 44 which divide the base sheet 12 may consist of creases which enable the folding of the base sheet where ultimate separation of the panels 33 from each other is not required or desired. Alternatively, however, the fold lines may 44 be formed by perforations or the like for folding the base sheet into a two-way mailer and allowing for separation of panels 33 from each other where separation is ultimately desired. Therefore, the term "fold line" as used herein means a portion of the base sheet 12 for purposes of folding the base sheet and does not necessarily include or exclude lines of perforations for the purpose of separating one panel from the other.

As depicted in FIGURES 1 and 2, it is preferred that the fold lines 44 between all panels 33 consist of a crease in the base sheet 12 except for fold line 46 which divides the back panel 36 and its adjoining panel 48 from the other base sheet panels. As explained in detail further herein, it is desired that fold line 46 be comprised of perforations or the like in order to facilitate removal of the return mailer from the base sheet. As shown in FIGURE 1, the front face 30 of the base sheet 12 provides for printing on all panels 33.

The front panel 24 provides outgoing mailing information 50 such as the receiver's name and address. Further, the front panel 24 provides return information 52 such as the sender's name and return address. Preferably, the outgoing mailing information 50 is printed generally in the center of panel 24 and the return information 52 is printed proximate to line 14 and 26. Printing of information in this manner provides for the terminal or open end of the mailer to extend along the top as described further herein.

The front face 30 of panel 48 which adjoins the back panel 36 also includes printed mailing information 54 such as the sender's name and address. In addition, space 56 on panel 48 includes the receiver's name and return address or, alternatively, blank lines for the receiver to write such information.

As described further herein, the front face 30 of panels 36 and 48 form the outside of a return mailer. Thus, although, panel 48 includes the sender's and receiver's names and addresses, it will be readily apparent after perusal of this specification and the claims that such information could just as well be printed on the front face 30 of the back panel 36 instead of panel 48. On the front face 30 of the intermediate panels between panel 48 and front panel 34 a blank 58 is provided for printing information or graphics media. The blank 58 extends between the lines of weakening 26 and 27 and may contain printed media such as advertisements or the like and be personalized to include information such as the receiver's name.

As shown in FIGURE 2, another blank 60 is provided on the rear face 32 of the front panel 34 and all of the intermediate panels 38 except for panel 48. Between the lines of weakening 26 and 27, the blank 60

SUBSTiTu SHEET VLB 26)

may contain printed or graphic advertisement media and may be personalized.

As will be appreciated by those skilled in the art, the ink coverage on banks 58 and 60 may be continuous between the panels because there are no gaps such as traverse glue bands or perforations between the blank panels. Further, it is preferred that printed media be applied to the blanks 58,60 before the fold lines are formed in order to provide a smooth surface for printing.

It is also preferred, but not necessary, that the perforations which form the lines of weakening 26,27, tear line 40, and fold line 46 be formed after printing. Further, it is desired that any glue or adhesive be applied to the rear face 32 of the base sheet 12 after printing.

In an embodiment, the base sheet 12 may also provide an area 61 on the blanks 58,60 for a membership card or the like. The area 61 may be surrounded by perforations, preferably formed after printing on the banks 58,60, for allowing a receiver to remove the membership card from the panel after opening the mailer.

As shown in FIGURE 2, two generally parallel glue lines 62 and 64 are applied to the side strips 28 and 29, respectively, on the rear face 32 of the base sheet 12. The glue lines 62,64 longitudinally extend along the base sheet 12 on front panel 34 and intermediate panels 38 with the tear lines 22 disposed exterior of the glue lines. Preferably, but not necessarily, the glue lines 62,64 have periodic gaps between adjoining panels 33 wherein the application of adhesive to the side strips 28 and 29 is omitted.

The panel 48 which adjoins to the back panel 36 also has disposed thereon two generally parallel adhesive lines 66 and 68 which longitudinally extend on the rear face 32 of the base sheet 12 interior of and

proximate to the lines of weakening 27 and 26, respectively.

Further, a traverse bend line 69 may be provided on panel 48. The bend line 69 is generally parallel with and proximate to fold line 46 and extends between the lines of weakening 26 and 27. The bend line

69 may consist of perforations or a score and, together with fold line 46, define a strip which is used as a flap for a return envelope as described further herein. A traverse band 70 of rewettable adhesive is also disposed generally parallel with and proximate to fold line 46 on the rear face 32 of panel 48. The band

70 of rewettable adhesive is disposed between fold line 46 and bend line 69 and is allowed to cure on panel 48 such that the adhesive will not attach to any other panel unless it is re-moistened.

In an alternative embodiment, the band 70 may consist of a contact adhesive which is protected by a peel-away protective strip overlaying the contact adhesive. The protective strip prevents the adhesive from attaching to another panel, but can be removed when such an attachment is desired such as when sealing a return envelope as described below.

As shown in FIGURES 3-5, base sheet 12 is assembled into a two-way mailer 71 with an integral return mailer consisting of a return envelope 72. The two-way mailer 71 is constructed by spirally wrapping front panel 34 and intermediate panels 38 around back panel 36 until all of the panels are sandwiched between panels 34 and 45. As indicated above, the return envelope 72 is constructed by back panel 36 and panel 48 which are overlaid against each other. The glue lines 62,64 and adhesive lines 66,68 on panel 48 secure the rear face 32 of panels 36 and 48 together to form the return envelope 72. The other panels are spirally wrapped around the envelope 72 such that the portion of

the glue line 62 and 64 on the rear face 32 of each panel attaches to the front face 30 of another panel. Correspondingly, the glue lines 62 and 64 preferably utilize a permanent adhesive which is sufficient to hold the panels together during mailing and handing.

To secure the area near the terminal end 74 of the front panel 34 to an intermediate panel 38, it is desired that a traverse band 76 of non-permanent glue be applied on the rear face 32 and parallel and proximate to the front panel terminal end. Preferably, the adhesive band 76 is of relatively low adhesive strength such that it allows for separating panel 34 from an intermitted panel 38 without tearing or otherwise defacing the panels. Securing the terminal end 74 to an intermediate panel 38 provides for sealing the mailer 71 along its top 77.

Before the two-way mailer 71 is ready to be sent in the mail, the drive tabs 24 and 25 are removed by pulling them away from each other such that they separate from the base sheet 12 along tear lines 22.

Removal of the drive tabs 24,25 will result in the side of the mailer 71 being sealed by adhesive lines 62 and 64.

The mailer ^' "! is opened by tearing along the lines of weakening 2c and 27 and removing side strips 28 and 29, respectively, and by pulling on front panel 34 to release adhesive band 76 from securing the front panel 34 from an intermediate panel 38. The panels are then unwrapped to reveal the information on the blanks 58,60 and the attached return envelope 72.

The return envelope 72 is separated from the other panels by tearing along perforated fold line 46. In addition, strip 42 is removed by tearing along perforated line 40 such that, as shown by FIGURE 6, a portion of panel 48 forms a flap 80 for securing contents within the envelope 72. The flap 80 is folded-

over along bend line 69 and the band 70 of rewettable adhesive is moistened in order to seal the envelope 72 by securing the flap to back panel 36. Further, as explained above, adhesive lines 66 and 68 secure each side of panels 36 and 48 to each other.

Although the adhesive lines 66 and 68 are depicted in FIGURES 1 and 2 as disposed on panel 48 of base sheet 12, it is readily apparent that the adhesive lines could instead be positioned onto back panel 36 since the purpose of the adhesive is to secure panels 48 and 36 together to provide a return envelope. Therefore, the present invention should not be limited to whether the adhesive lines 66 and 68 are first applied to panel 48 or 36. Likewise, the present invention should not be limited to whether adhesive lines 66 and 68 extend onto back panel 36 since the adhesives lines serve to secure panels 36 and 48 together during construction of the mailer. Further, it is desired that all adhesives and glues applied to the base sheet 12 to form the mailer 71 and return envelope 72 use standard compounds which are environmentally friendly and thus break-down relatively quickly.

In an alternative embodiment, the two-way mailer 71 may include an integral return mailer consisting of a rigid multi-ply postcard formed by at least two or more panels. Preferably, the postcard has only two-plies wherein each ply is provided by panels 36 and 48, respectively, with the adhesive lines 66,68 and band 70 securing the rear face 32 of the panels together during the folding of base sheet 12 into a two-way mailer as described above. Therefore, when the recipient opens the mailer 71, a rigid two-ply return postcard is provided instead of a return envelope. If the postcard is provided within the two-way mailer instead of a return envelope, it is desired that

band 70 consists of a standard contact adhesive or the like for attaching the panels 36 and 48 together during folding of the mailer 71. Further, bend line 69 and tear line 40 should be omitted since the panels 36,48 are completely seal together by adhesive lines 66,68 and band 70 in order to from the return postcard.

Another base sheet 112 for constructing a two- way mailer embodying the present invention is depicted in FIGURES 7 and 8. The base sheet 112 is similar to the base sheet 12 illustrated in FIGURES 1 and 2 except for the number of panels and the addition of a bang tail 182 to the back panel 136. The embodiment depicted in FIGURES 7 and 8 is otherwise similar to the embodiment depicted in FIGURES 1 and 2 and has the same general construction.

With regard to FIGURES 7 and 8, four panels 133 are provided on base sheet 112 which is separated from a continuous web. The base sheet 112 is provided with drive tabs 124 and 125 for facilitating the printing and assembling of the base sheet into a two-way mailer by using a conventional tractor feed or the like.

During processing of the web, the bang tail 182 is formed by die-cutting. Preferably, the bang tail 182 has a traverse length 184 which is less than the distance between adhesive lines 166 and 148. Further, the width 186 of the bang tail 182 is less than the width of the back panel 136 from the fold line 144 to tear line 140.

As shown in FIGURES 7 and 8, the front face 130 and rear face 132 of the bang tail 182 provides for printing an order form, information, or graphics media. The bang tail 182 adjoins the back panel 136 with a traverse fold line 184 between the back panel and the bang tail. The traverse fold line 184 is formed by a plurality of perforations or the like and is generally parallel with line 140 and fold lines 144. The traverse

fold line 184 provides for removing the bang tail 182 from the base sheet 112 as described further herein. Preferably, in order to provide a smooth surface for printing on the base sheet 112, any printing on the bang tail 182 is performed before formation of the fold lines 144, lines of weakening 126,127, tear line 140, fold line 146, or fold line 184.

The base sheet 112 is assembled into a two-way mailer with an integral return mailer, consisting of a return envelope, in a manner similar to that described above. The bang tail can be overlaided against either the front face 30 or the rear face 32 of the back panel 136. Then, the front panel 134 and intermediate panels 138 are spirally-wrapped around back panel 136 until all of the panels are sandwiched between panels 134 and 145. As indicated above, the panels 133 form a mailer with a return envelope which is secured together by glue lines 162,164.

The mailer is opened by tearing along the lines of weakening 126 and 127 and removing side strips 128 and 129, respectively, and by also pulling on front panel 134 to release adhesive band 176 from securing the front panel to panel 148. The panels are then unwrapped to reveal the information on the blanks 158,160, the attached return envelope, and bang tail 182.

The return envelope and bang tail 182 are separated from the other panels by tearing along perforated fold line 146. In addition, strip 142 and bang tail 182 are removed by tearing along perforated lines 140 and 184, respectively. Correspondence can then be written on the bang tail 182 and sealed within the return envelope provided by panels 148 and 142.

It will be readily apparent from the foregoing detailed description of the invention and from the illustrations thereof that numerous variations and modifications may be effected without departing from the

true spirit and scope of the novel concepts or principles of this invention.