AU2005227394A1 - An Improved Mailer - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Applicant: An Improved Mailer dot2dot Post Pty Ltd The following statement is a full description of this invention, including the best method of performing it known to me: -2- 'n An Improved Mailer Field of the Invention oO 5 The present invention relates to one-piece mailers of the type which are not constructed from an intermediate or special form. The invention also relates to methods and apparatus for forming such one-piece mailers.

Backqround of the Invention Reusable envelopes are becoming increasingly popular because they save paper usage. Such envelopes are typically designed so that the initial sender inserts the letter into the envelope through a sealable flap. The first recipient's address details are then visible through a window in the envelope. The sealable flap is usually located along one of the long sides of the envelope. The envelope has another flap, usually an end flap, sealed with releasable glue.

The recipient opens the envelope via the end flap and removes the letter. For return, the recipient inserts a letter into the envelope via the end flap and then reseals the end flap on the outside of the envelope. The letter is placed in the envelope so that only blank paper is visible through the window. The second recipient's address details are on the back of the envelope.

While the above form of reusable envelope saves paper in that the envelope is used for both the initial and return mailings, it is desirable to further reduce paper usage. To this end, one piece mailers have been developed. Such mailers are formed from a single piece of paper which serves as both the sheet on which the letter is written and the envelope.

One piece mailers are made from an intermediate form which is specially designed for a particular use. Accordingly, the intermediate form not only has the glue pre-applied, but also is pre-printed with general information relevant to the particular use. The customer then prints additional information onto the intermediate form, prior to sealing and sending the mailer to a recipient. An example of such an intermediate form is a salary statement or an invoice.

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O Typically, the intermediate form has a heat seal glue applied so that when the form is subsequently folded, it can be sealed in such a way that the blank side O of the form forms the envelope. A problem with this type of intermediate form 0, 5 is that when the form is subsequently passed through a laser printer or other printer requiring heat, the glue is activated and damage to the printer and letter itself often occurs.

US 4,951,864 attempts to solve the problem by the addition of remoistenable glue strips or lines. Thus, the intermediate form can pass through a printer, such as a laser printer, without activation of the glue strips or lines. The form then passes through a folder, water being applied to the glue prior to or as the form passes through a folding machine and then pressure is applied to the folded form to seal the edges and thus form a one-piece mailer.

US 5,513,795, US 6,412,687, US 6,422,938 and US 6,431,437 address the problems associated with the use of a heat seal glue by instead using a pressure seal adhesive or cohesive. With such adhesives, the application of high pressure to the folded intermediate form activates the cohesive.

Accordingly, the intermediate form can be laser printed without activating the cohesive.

As intermediate forms are specifically designed for a particular use/application they are very expensive when compared to the cost of a plain sheet of paper.

The present invention seeks to provide a one-piece mailer that is made from a plain sheet of paper one that does not require a specialised intermediate form).

The discussion of the background to the invention herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of this application.

-4- 0 Summary of the Invention

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According to a first aspect of the present invention there is provided a method of O forming a mailer, said method including the steps of: 00 5 a) printing a standard sheet of paper with information; b) applying adhesive to the standard sheet of paper; and c) folding the standard sheet of paper in a folding machine so as to form at least one fold line in said sheet of paper, and wherein the pressure applied by the folding machine to the sheet of paper causes the adhesive to adhere together overlapped portions of the sheet of paper thereby forming said mailer.

Preferably, the information printed on the sheet includes address details of a first recipient or address details for second recipient or address details for both a first and a second recipient.

Preferably, the adhesive is applied to only one side of the sheet of paper. This side is referred to hereinafter as the "first side".

The adhesive is preferably releasable so that the mailer can be subsequently unfolded without tearing or damaging of the sheet of paper.

The adhesive may be both releasable and one which is reusable so that the sheet can be refolded and adhered using the same adhesive after an initial unfolding.

The adhesive may be glue, such as hot melt glue. The hot melt glue should have the desired tack, adhesion and cohesion to ensure that the glue is releasable, or releasable and not reusable, or releasable and reusable depending on the nature of the mailer.

Preferably, the step of folding the standard sheet of paper includes forming two fold lines in the sheet so that the sheet can be C-folded so that a first fold along a first folding line brings a leading end panel into contact with a middle panel n and a second fold on a second folding line brings a trailing panel into contact 0 with a second side of the leading panel.

O The adhesive is preferably applied adjacent each of the side edges of the sheet.

00 5 The side edges are the edges of the sheet substantially perpendicular to the direction of the folding lines.

In one embodiment of the invention, the adhesive is applied adjacent the side (edges of the middle and trailing panels of the sheet.

The adhesive may be continuous or discontinuous across the panels.

In accordance with a preferred embodiment of the invention, a coating may be applied to zones on the sheet of paper prior to applying the adhesive. When the mailer is opened, that is moved from a folded condition to an unfolded condition, the adhesive which was located on the coating prior to folding is released from the coating and is instead adhered to that part of the sheet which was in contact with the adhesive when the sheet of paper was first folded.

The properties of the coating and the adhesive and their location and coverage should be selected so as to provide the required degree of adhesion between the panels of the sheet. The required degree of adhesion will depend on the nature of the mailer. For example, in accordance with some embodiments of the invention, it is desirable for the mailer to be firmly secured when it is sent from the original sender to a first recipient. Accordingly, the coating and adhesive should be selected so as to adequately secure the sheet in the folded condition whilst still enabling release of the adhesive from the coating when sufficient force is applied by the recipient when opening the mailer. For those embodiments, the mailer is considered to be "adequately secured" if the sheet does not inadvertently open or begin to open prior to deliberate opening by the recipient. The coating and adhesive may be selected so that any tampering with the mailer can be readily detected.

-6- In other embodiments, it may be desirable for the mailer to be received by the Sfirst recipient in a form that is readily opened, to the extent that any adhesion by the adhesive to the coating would not be noticed by the first recipient. With 0 such embodiments it may also be desirable for the mailer to be mailed to a second recipient in an adequately secured manner. This means that the adhesive and coating should be selected so that when the sheet is folded a second time to enable it to be mailed to the second recipient, it will be secured so that it does not inadvertently open or begin to open prior to deliberate opening by the recipient.

In some embodiments, it is desirable to ensure that the mailer is sealed so that information contained within the mailer cannot be viewed by a non intended recipient. In other embodiments, the mailer need only be secured in a manner sufficient to satisfy the requirements of the relevant postal authority.

The coating may be applied to the first side of the sheet and/or the second side of the sheet.

The coating is preferably applied adjacent the side edges of the sheet. The coating may be applied in a continuous or discontinuous manner between the leading and trailing edges of the sheet.

The width of the coating is preferably slighter greater than the width of the adhesive applied to the sheet so that adhesive can be easily applied on top of at least parts of the coating.

In accordance with a preferred embodiment of the invention the coating includes an edge coating and a central coating. The edge coating is applied to the first side of the middle panel of the sheet adjacent each of the side edges and to the second side of the leading panel adjacent each of the side edges.

The central coating may include a coating applied at least at a second location on the first side of the middle panel, between the side edges of the sheet and adjacent to the second folding line. The central coating may also include a -7coating applied at least at a second location on the second side of the leading Spanel between the side edges of the sheet and adjacent the first folding line.

O Adhesive is applied on top of the edge coating on the middle panel and 00 0 5 adhesive may also be applied adjacent the side edges of the trailing panel.

Adhesive may also be applied on top of the central coating at the second location on the middle panel. Adhesive may also be applied at least at a central location on the trailing panel, between the side edges of the sheet and adjacent to the trailing edge of the sheet.

The edge coating on the leading panel and the adhesive adjacent the side edges of the trailing panel are positioned so that when the second fold is made the adhesive adjacent the side edges of the trailing panel contacts the edge coating on the second side of the leading panel.

The central coating on the leading panel and the adhesive at the second location on the trailing panel are positioned so that when the second fold is made, the adhesive at the second location on the trailing panel contacts the central coating on the second side of the leading panel.

When the mailer is opened along the second folding line by the first recipient, the adhesive adjacent the side edges and at the second location on the trailing panel is retained on the trailing panel. The adhesive is retained on the trailing panel in preference to the second side of the leading panel because of the edge and central coatings which reduce the adhesive force to the leading panel.

When the mailer is opened along the first folding line by the first recipient, the adhesive originally on the middle panel is adhered to the first side of the leading panel. The adhesive on the middle panel migrates from the middle panel to the leading panel because of the coatings on the middle panel. These coatings reduce the adhesive force of the adhesive to the middle panel thereby causing the adhesive to preferentially adhere to the leading panel.

-8- According to a second aspect of the invention there is provided a mailer made 0 in accordance with the first aspect of the invention.

O In accordance with one embodiment of the second aspect of the invention the 00 0 5 mailer includes a sheet of paper including a leading edge, a trailing edge, opposed side edges, an imaginary first folding line and an imaginary second folding line, the leading edge and the imaginary first folding line bounding a leading panel, the first and second imaginary folding lines bounding a middle panel and the imaginary second folding line and the trailing edge bounding a trailing panel, adhesive applied to the middle and trailing panels of a first side of the sheet of paper, information for a first recipient applied to the first side of the sheet of paper and at least first or second recipient's address detailed applied to a second side of the sheet of paper.

According to a third aspect of the invention there is provide a folding and sealing machine including means for feeding a standard sheet of paper into the sealing machine, a first sensor means for detecting the sheet of paper, means for applying glue to the sheet following detection of the sheet by the first sensor means, means for making a first fold in the sheet and means for making a second fold in said sheet.

Preferably, the means for making the first fold in the sheet and the means for making the second fold in the sheet are each arranged so as to prevent contact with the adhesive applied to the sheet.

Preferably, the folding and sealing machine includes a second sensor means arranged to detect that the sheet fed into the machine has been received by the first folding means. Preferably, the folding and sealing machine ceases operation if the second sensor means fails to detect that the sheet has been received by the first folding means within a preset time frame.

Throughout this specification and the claims the term "standard sheet of paper" includes for example photocopying and printing paper, plain paper, coloured -9paper, textured paper, plain board, coloured board and textured board. It will of Scourse be appreciated that a reference to "printing a standard sheet of paper with information" also includes arrangements where large sheets of paper are o printed and then cut down to form multiple standard sheets of paper with 0 5 printing thereon or arrangements wherein paper in roll form is printed and then cut down to form multiple standard sheets of paper with printing thereon. A "standard sheet of paper" does not include an intermediate form or special form.

CExamples of intermediate forms are shown in US 6,431,437, US 6,422,938 and SUS 4,951,864.

i It should be appreciated that throughout the specification and claims the term "mailer" is used generically and should be understood to include, but not be limited to, a one-piece mailer, a one-piece mailer with second recipient details, a one-piece mailer with first and second recipient details, a one-piece mailer with one or more removable portions, a one-piece mailer with tear-off strips, a single-fold one-piece mailer, an adherable brochure, a re-adherable brochure and a mailer greeting card.

Description of the Drawings Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a schematic end view of a folding and sealing machine in accordance with an embodiment of the invention; Figure 2 is a plan view of the folding and sealing machine shown in Figure 1; Figure 3 is a plan view of the first side of a mailer according to a first embodiment of the invention; Figure 4 is a plan view of the second side of the one piece mailer shown in Figure 3; Figure 5 is an end view showing a first fold being made in a mailer according to an embodiment of the invention; 00 0Figure 6 is an end view showing a second fold being made in a mailer according to an embodiment of the invention; CFigure 7 is a plan view of the first side of a mailer according to a second N embodiment of the invention; Figure 8 is a plan view of the second side of the mailer shown in Figure 7; Figure 9 is a plan view of the first side of a mailer according to a third embodiment of the invention; Figure 10 is a plan view of the second side of the mailer shown in Figure 9; Figure 11 is a plan view of the first side of a mailer according to a fourth 20 embodiment of the invention; Figure 12 is a plan view of the second side of the mailer shown in Figure 11 Figure 13 is a plan view of the first side of a mailer according to a fifth embodiment of the invention; Figure 14 is a plan view of the second side of the mailer shown in Figure 13; Figure 15 is a plan view of the first side of a mailer according to a sixth embodiment of the invention; Figure 16 is a plan view of the second side of the mailer shown in Figure -11 Figure 17 is a plan view of the first side of a mailer according to a seventh Sembodiment of the invention; and o Figure 18 is a plan view of the second side of the mailer shown in Figure 17.

00 Detailed Description of the Preferred Embodiments Figures 1 and 2 illustrate a sheet 1 of paper entering a folding and sealing Ni machine 100. The sheet 1 is a standard sheet of paper. In this exemplary embodiment, the sheet 1 is an A4 size sheet of copy paper.

The folding and sealing machine 100 of this embodiment seals the sheet 1 to form a mailer using hot melt glue. It should be appreciated that the machine 100 could readily be modified to use other forms of adhesive and the present invention should not be limited to use of hot melt glue as the adhesive.

The folding and sealing machine 100 includes a feed roller 2, a first sensor 3, four glue modules 4 each having a glue nozzle 5, curved plate 6, folding rollers 7, 8, 11 and 13, a second sensor 9, first folding plate 10 and second folding plate 12.

The first and third folding rollers 7, 11 and first and second folding plates 10, 12 are specially formed so that glue applied to the sheet 1 from the glue nozzles does not come into contact therewith. As best shown in Figure 2, the first and third folding rollers 7, 11 include recessed sections 14 to prevent the glue making contact therewith. The first folding plate 10 includes cut away sections (not shown) to prevent contact with any glue on the sheet 1.

The folding and sealing machine 100 is arranged to make first and second folds along the first and second folding lines 15, 16 of the sheet. Such folding lines will be further described in relation to the various sheets shown in Figures 3 to 16. The first and second folding lines 15, 16 define a trailing panel 17, a middle panel 18 and a leading panel 19 in the sheet 1.

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O Figures 1 and 2 illustrate the sheet 1 in position ready to be picked up by the feed roller 2. As the feed roller 2 feeds the sheet 1 into the machine 100, the o first sensor 3 detects the leading edge l a of the sheet 1. The hot melt glue S 5 modules 4 are then activated to extrude glue from their respective glue nozzles and to apply the glue to the upper side of the sheet 1.

The curved plate 6 of the machine 100 guides the leading edge l a of the sheet N-1 between the first folding roller 7 and the second folding roller 8. As shown, rollers 7 and 8 rotate in opposite directions. The second sensor 9 detects the 0 leading edge l a of the sheet 1 as it enters a first folding plate 10. If the leading edge l a of the sheet 1 is not detected by the second sensor 9 within a pre-set time frame, the machine 100 is automatically shut down. This shut down prevents further sheets 1 from being fed into the machine 100. Accordingly, a multiple sheet blockage within the machine 100 is prevented. The shut down also prevents any further application of glue which if not applied correctly to a sheet 1 may inadvertently come into contact with various components of the machine 100, such a the rollers 7, 8, 11, 13.

When the leading edge la of the sheet 1 hits the stop (not shown) of the first folding plate 10, the sheet 1 is prevented from advancing further. A portion of the sheet 1 adjacent the opening of the first folding plate 10 is then bent and the bent portion is nipped between the second folding roller 8 and the third folding roller 11 thus forming the first fold in the sheet 1. The first fold of the sheet 1 then enters the second folding plate 12 until the first fold hits a stop (not shown) of the second folding plate 12. A portion of the sheet 1 adjacent the opening of the second folding plate 12 is then bent. The bent portion is nipped between the second folding roller 8 and a fourth folding roller 13 forming the second fold in the sheet 1. The second fold is formed and passes between the second folding roller 8 and fourth folding roller 13 so that the leading panel 19 is located between the middle panel 18 and the trailing panel 17. The panels 17, 18, 19 are pressed together to seal the folded sheet 1 together as it passes through the rollers 8, 13. The roller 13 may have shallow recesses (not shown) in line -13with the recesses 14 in rollers 7, 11 to control the pressure applied to the glue 0 20. The resultant folded and adhered sheet 1 forms a mailer in accordance with

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an embodiment of the invention. Various mailers will be described in more O detail below with reference to Figures 3 to 16.

00 Figures 3 and 4 illustrate a sheet 150 for forming a mailer including a first recipient's address details. This type of mailer is intended to be posted or Sotherwise delivered to the first recipient. It is not intended for reuse as a mailer.

Figure 3 illustrates the side of the sheet 150 to which glue 20 is applied. This side will hereinafter be referred to as the "first side". The other side of the sheet 1 will hereinafter be referred to as the "second side". The first side of the sheet 150 would typically have printed thereon information for the first recipient. The information could adopt many different forms, but typically would be a letter to the first recipient.

The sheet 150 is shown with a first folding line 15 along which the first fold is subsequently made and a second folding line 16 along which the second fold is subsequently made. It will of course be appreciated that the first and second folding lines 15, 16 are shown in Figures 3 and 4 to aid the description and are not actual "lines" printed/marked on the sheet 150. The first and second folding lines 15, 16 are thus "imaginary lines" prior to folding of the sheet 150.

The second side of the sheet 150 is shown in Figure 4. Located on the trailing panel 17 on the second side of the sheet 150 are the first recipient's address details 21.

The glue 20 used on the sheet 150 is of a type that is both releasable and removable. It is "releasable" because it enables the first recipient to unfold the mailer without tearing or damaging of the sheet 150. It is "removable" because it can be easily and cleanly removed simply by rubbing it off with ones fingers.

-14- As shown in Figure 3, glue 20 is applied adjacent to the side edges I b of the 0sheet 150 on both the middle panel 18 and to the trailing panel 17. The glue

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is shown as being applied as multiple beads of glue across each panel 17, 18 0 the glue is applied in a discontinuous manner). It should be appreciated 0 5 that the glue 20 may be applied in a continuous manner across each of the panels 17, 18.

Glue 20 is also applied at two positions adjacent the trailing edge Ic of the sheet 150. The glue 20 adjacent the trailing edge Ic of the sheet 150 helps to further secure the mailer as will be better described subsequently.

In order to form a mailer, the sheet 150 is first printed with relevant information, including the first recipient's address details 21. The printed sheet 150 is then fed through the machine 100 wherein it is folded to form the mailer. The first fold on the first folding line 15 brings the leading panel 19 into contact with the glue 20 on the middle panel 18 (Figure The second fold on the second folding line 16 brings the glue 20 on the trailing panel 17 into contact with the second side of the leading panel 19 (Figure The recipient's address details 21 are clearly visible on the outside of the completed mailer. This type of fold is called a Cfold.

When the mailer is opened by the recipient, the glue 20 can be easily and cleanly removed from the sheet 150 by rubbing it off with ones fingers. This enables the recipient to subsequently store/use the sheet 150 as if the sheet had been forwarded in a conventional envelope rather than as a one-piece mailer.

It will be appreciated by those skilled in the art that by varying the type, positioning and coverage of the glue 20 it is possible to vary the manner in which the mailer is secured/sealed. If the information printed on the sheet 1 is of a confidential nature then the glue 20 should be such as to secure the mailer in a manner which prevents that information from being seen by a non authorised party. If the information on the sheet 1 is of a different nature, it may be sufficient for the glue 20 to simply secure the mailer so that it meets the Srequirements of the relevant postal authority.

o 5 Figures 7 and 8 illustrate a sheet 200 for a mailer including both a first 00 0 recipient's address details and a second recipient's address details. This type of mailer is intended to be mailed to the second recipient after the first recipient has read the original information on the mailer and then provided some additonal information thereon. An example of such additional information would be a request to purchase tickets and payment details.

The second recipient's address details typically include a reply paid address so as to prevent the first recipient from having to pay for the return postage and thus increase the likelihood of the first recipient returning the mailer 200 to the second recipient. The inclusion of the second recipient's address also ensures that the first recipient does not inadvertently use an incorrect retumrn address.

As the mailer in Figures 7 and 8 is designed for a second use, its construction is different to the mailer previously described in relation to Figures 3 and 4.

Additionally, the glue used in the construction of the mailer shown in Figures 7 and 8 should have properties to ensure that the glue is releasable and reusable.

Figure 7 shows the front or first side of the sheet 200 which forms the mailer.

For consistency and ease of description, the sheet 200 is shown as including a first folding line 15, a second folding line 16, a trailing panel 17, middle panel 18 and a leading panel 19.

Figure 8 shows the second side of the sheet 200 forming the mailer. The address details of the first recipient 21 are shown on the trailing panel 17 and the address details of the second recipient 31 are shown on the leading panel 19. The second recipient's address details 31 are printed in the opposite orientation to that of the first recipient's address details 21.

-16- SAn edge coating 23a is applied to areas adjacent the side edges I b of the 0 middle panel 18 on the first side of the sheet 200 and areas adjacent the side

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Sedges lb of the leading panel 19 on the second side of the sheet 200. As O illustrated the edge coating 23a on the middle panel 18 extends between the first folding line 15 and the second folding line 16. The edge coating 23a on the leading panel 19 extends between the leading edge la of the sheet 1 and the first folding line (Ni N' A central coating 23b is also applied to the first side of the middle panel 18 and the second side of the leading panel 19. The central coating 23b of each of the 0 middle and leading panels 18, 19 of this embodiment includes two lengths of coating 23b. Each length of coating 23b being positioned approximately 1 /3rd the width of the sheet 200 away from the respective side edges I b of the sheet 200. The term "central coating" is used to refer to a coating other than the edge coating 23a and it will be appreciated that the "central coating" may be located anywhere across the width of the sheet 200.

The edge and central coatings 23a, 23b are typically the same coating and are typically applied as strips of coating. A varnish, such as an offset printing varnish is suitable as a coating when the adhesive used is hot melt glue. Such a varnish could be applied as part of the printing process when the sheet 200 is printed with information.

The coatings 23a, 23b should be selected so that they enable the hot melt glue to adequately secure the sheet 200 in the folded condition whilst still enabling release of the glue from the coatings 23a, 23b, as will be described in more detail below, when sufficient force is applied by the first recipient when opening the mailer. The mailer is considered to be "adequately secured" if the sheet 200 does not inadvertently open or begin to open prior to deliberate opening by the first recipient.

As shown in Figure 7, glue 22a is applied on top of the edge coating 23a on the middle panel 18. More particularly, the glue 22a is applied so that it extends -17from the second folding line 16. Glue 22b is also applied on the central coating 0 23b on the middle panel 18.

o Glue 22c is also applied adjacent the edge I b of the trailing panel 17 and glue 00 5 22d is also applied on a second location on the trailing panel 17. The glue 22d on the trailing panel 17 and the central coatings 23b on the leading panel 19 are positioned so that when a fold is made along the second folding line 16, the glue 22d on the trailing panel 17 contacts the central coating 23b on the second side of the folded leading panel 19.

i When the sheet 200 shown in Figures 7 and 8 is folded in the folding machine 100, the first fold on the first folding line 15 brings the leading panel 15 into contact with the glue 22a, 22b on the middle panel 18. The second fold on the second folding line 16 brings the glue 22c, 22d on the trailing panel 17 into contact with edge and central coatings 23a, 23b on the second side of the leading panel 19.

When the mailer is received by the first recipient, it is opened by carefully pulling the trailing panel 17 away from the leading panel 19 unfolding the second fold). As this occurs, glue 22c, 22d originally applied to the trailing panel 17 pulls away from the second side of the leading panel 19 and is retained on the trailing panel 17. The glue 22c, 22d is retained on the trailing panel 17 in preference to the second side of the leading panel 19 because of the edge and central coatings 23a, 23b which reduce the adhesive force to the leading panel 19.

When the mailer is opened along the first folding line 15 by the first recipient, the glue 22a, 22b originally on the middle panel 18 is adhered to the first side of the leading panel 19. The glue 22a, 22b on the middle panel 18 migrates from the middle panel 18 to the leading panel 17 because of the coatings 23a, 23b on the middle panel 18. These coatings 23a, 23b reduce the adhesive force of the glue 22a, 22b to the middle panel 18 thereby causing the glue 22a, 22b to preferentially adhere to the leading panel 19.

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O The information printed on the mailer can then be read by the first recipient and reply information added to the mailer. For example, the mailer could be a O request from a charity for a donation from the first recipient. If the first recipient 5 desires to make a donation, the first recipient completes the donation payment details credit card details) and then refolds the mailer by hand so that it can then be posted or otherwise returned to the second recipient.

The sheet 200 must be refolded so that the second recipient's details 31 are visible. This is achieved by making a first fold along the original second folding line 16 so that the first side of the trailing panel 17 is brought into contact with the middle panel 16. The glue 22c, 22d on the first side of the trailing panel 17 will adhere the trailing panel 17 to the middle panel 16.

A second fold is then made on the original first folding line 15 so that the leading panel 19 is brought into contact with the second side of the trailing panel 17.

The glue 22a, 22b which was transferred from the middle panel 18 to the first side of the leading panel 19 will adhere the leading panel 19 to the second side of the trailing panel 17. In this manner, the folded sheet 200 is formed as a mailer with the second recipient's address details 31 exposed. Importantly, for security reasons, both the first recipient's details 21 and the reply information they provided are contained "within" the mailer so that they cannot be inadvertently seen whilst the mailer remains in the folded configuration prior to opening by the second recipient.

A particularly advantageous feature of the mailer shown in Figures 7 and 8 is the manner in which the leading panel 19 is adhered to the second side of the trailing panel 17 when the mailer is returned to the second recipient. Most importantly, the migrated glue extends from substantially the leading edge 1 a of the sheet 200. This means that when the leading panel 19 is folded so as to come into contact to the second side of the trailing panel 17, there is an amount of glue located substantially at the leading edge la. This helps prevent the leading edge la from being inadvertently pulled away from the trailing panel 17.

-19- It will be appreciated by those skilled in the art that the folding and sealing Smachine 100 shown in Figure 1 cannot apply glue substantially at the leading edge la of the sheet. This is because the sensor 3 of the machine 100 only O registers the presence of the leading edge la of the sheet 200 after it has OO 00 passed the glue nozzles Figures 9 and 10 illustrate a sheet 250 which forms a mailer in accordance with another embodiment of the invention. The sheet 250 is very similar to the sheet 200 shown in Figures 7 and 8. However, it does not include any first S 10 recipient details and the location and amount of the applied glue on the trailing panel 17 is different. Additionally, the sheet 250 does not include any central coating 23b on the second side of the leading panel 19.

The mailer produced using the sheet 250 is useful as a brochure that is not intended to be personally mailed to the first recipient. Rather it is intended to be distributed to the first recipient by other means such as insertion in magazines and newspapers etc. Accordingly, when the mailer is received by the first recipient it is not necessary or may not be desirable for the panels 17, 18, 19 of the sheet 250 to be adhered securely together. Rather, it may be preferable that there is little or no effective adhesion between the panels 17, 18, 19 so that the mailer opens like a simple C-folded brochure.

The mailer produced using the sheet 250 is intended to be mailed to a second recipient. Accordingly, it includes the address details of the second recipient 31 so that it can be readily returned to the second recipient. When the mailer is posted to the second recipient, the mailer may contain confidential information.

If this is the case, it is desirable to ensure that the mailer is secured in a sealed fashion so as to prevent inadvertent disclosure of the confidential information.

The glue and coatings used on the sheet 250 should be selected to take into consideration the requirements mentioned in the previous two paragraphs.

The sheet 250 can be unfolded and refolded as described previously in relation 0 to the sheet 200. Alternatively, the trailing panel 17 of the sheet 250 can be

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removed by the first recipient by tearing along an optional line of weakness O extending along the first folding line 16. The leading panel 19 can then be 0 5 folded and glued into contact with the middle panel 18 so that the second recipient address details 31 are exposed. It will of course be appreciated that the trailing panel 17 of the sheet 200 shown in Figures 7 and 8 could also be similarly removed.

It may be desirable for the first recipient to retain the trailing panel 17 in some circumstances. For example, the trailing panel 17 may adopt the form of an entry ticket, an order confirmation, payment confirmation etc that may be needed by the first recipient at a later time.

Figures 11 and 12 illustrate a sheet 300 for producing another form of mailer.

This type of mailer would, for example, be used to send confidential information to a first recipient. Accordingly, it is important that the sheet 300 forming the mailer is sealed so as to prevent inadvertent access to the information contained in the mailer. Additionally, it is desirable to ensure that any tampering of the mailer is obvious. To this end, it is preferable for the adhesive to strongly adhere the panels 17, 18, 19 of the sheet 300 together so that any attempt to open the mailer by pulling the panels 17, 18, 19 will be apparent.

The sheet 300 is similar to the sheet 150 shown in Figures 3 and 4 but includes a central coating 23b on the second side of the leading panel 19. The mailer 300 also includes tear-off strips 51. The tear-off strips 51 provide the mechanism by which the first recipient opens the mailer.

The mailer 300 is folded in the same manner as previously described. The perforations which define the tear-off strips 51 can be formed in the sheet 300 prior to feeding it into the folding and sealing machine 100 or may be formed in the sheet 300 by a modified form of the machine 100.

-21 When the mailer 300 is received by the first recipient it is opened by tearing off Sthe tear-off strips 51. The trailing panel 17 is then pulled away from the second side of the leading panel 19. The glue 22d on the trailing panel 17 is retained o on the retaining panel 17 because of the coating 23b on the leading panel 19.

00 Figures 13 and 14 illustrate a sheet 350 for another form of mailer which is intended to be used as a greeting card. The sheet 350 has glue 22a, 22c, 22d Sand coatings 23a, 23b as indicated. It is folded in the same manner as described in relation to the previous embodiments.

S Upon receipt by the first recipient, the mailer is opened by pulling the trailing panel 17 away from the leading panel 19. Due to the coatings 23a, 23b on the second side of the leading panel 19, the glue 22c, 22d originally applied to the trailing panel 17 is retained thereon when the mailer is opened by the recipient.

The leading panel 19 is then pulled away from the middle panel 18. Again, due to the coating 23a on the first side of the leading panel 19, the glue 22a originally applied to the middle panel 18 is retained thereon.

The recipient then folds the trailing panel 17 into contact with the middle panel 18 so that they adhere together and so that there is no exposed glue on the sheet 350. The sheet 350 thus folded forms a conventional type greeting card that can be stood to be displayed. The sheet 350 used to form the mailer is preferably made of a relatively stiff paper to enable the greeting card to be readily displayed in an upright position.

Figures 15 and 16 illustrate a sheet 400 for another form of mailer. Such a mailer is intended to be used as a brochure with a return address capability.

The sheet 400 is very similar to the sheet 250 described previously with respect to Figures 9 and 10. It will be appreciated however that the exact positioning of the glue 22a, 22c and the coatings 23a, 23b on the panels 17, 18, 19 varies slightly.

The mailer formed by the sheet 400 is intended to appear to the first recipient as a conventional brochure. Accordingly, it is desirable that the glue 22a, 22c -22does not adhere or only adheres very weakly to the coatings 23a, 23b. This Senables the brochure to be opened very easily by the first recipient, almost in the same fashion as they would open a conventional C-fold brochure.

0 0 5 When the mailer is opened, the glue 22c is retained on the trailing panel 17 and

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the glue 22a, 22b originally on the middle panel 18 migrates to the first side of ,I the leading panel 19.

(Ni The sheet 400 can be refolded so that the address details of the second recipient 31 are exposed. To achieve this, the trailing panel 17 is folded along folding line 16 so that the trailing panel contacts the middle panel 18. The glue 22c on the trailing panel 17 thus contacts an uncoated part of the middle panel 18 to adhere the trailing and middle panels 17, 18 together.

The leading panel 19 is then folded onto the second side of the trailing panel 17. The glue 22a, 22b that migrated from middle panel 18 so as to be located on the leading panel 19 adheres the leading panel 19 to the second side of the trailing panel 17.

It will be noted that in accordance with the embodiment of the invention shown in Figures 15 and 16, the coatings 23a, 23b on the middle panel 18 do not overlap the coatings 23a on the second side of the leading panel 19 when they are in a folded condition.

Figures 17 and 18 illustrate a sheet 450 which forms a mailer in accordance with a seventh embodiment of the invention. The sheet 450 is similar to the sheet 200 shown in Figures 7 and 8. However, sheet 450 includes an additional coating 32 on the first side. The additional coating 32 is applied on the middle panel 18 adjacent the first folding line 15, adjacent the side edges I b of the middle panel 18 and trailing panel 17 and adjacent the trailing edge ic of the trailing panel 17. The additional coating 32 does not overlap the coating 23a and is applied prior to applying the glue 22a, 22b, 22c, 22d.

-23- I Sheet 450 is folded along the first and second folding lines 15, 16 as described Spreviously in relation to the earlier embodiments to form a mailer. The resultant mailer would, for example, be used by a first recipient to send confidential o information to a second recipient. The additional coating 32 or "adhesive" 0 5 coating as it is hereafter referred to has properties such that when a portion of the adhesive coating 32 makes contact with another portion of the adhesive coating 32, the two portions adhere to each other in a manner consistent with the intended use of the mailer. However, when a portion of the adhesive icoating 32 makes contact with an uncoated portion of the sheet 450, the two portions do not adhere to one another. An example of a suitable adhesive coating 32 is the water-based latex adhesive used to seal the flap of self-seal envelopes.

When the mailer is opened by the first recipient, the adhesive coating 32 is only in contact with uncoated surfaces of the sheet 450 and thus the adhesive coating 32 does not impede the opening of the mailer. When the first recipient refolds the mailer for mailing to the second recipient, the first fold along the second folding line 16 ensures that the adhesive coating 32 on the first side of the trailing panel 17 will adhere to the adhesive coating 32 on the first side of the middle panel 18 so as to thus form a sealed envelope. The first recipient may enclose an insert such as a cheque into this "envelope" prior to sealing.

When a second fold is made along the first folding line 15, the glue 22a, 22b, which was transferred from the middle panel 18 to the first side of the leading panel 19 when the mailer was originally opened, will adhere the leading panel 19 to the second side of the trailing panel 17.

The adhesive coating 32 may be selected according to the desired level of security required when the mailer is forwarded to the second recipient.

It is also envisaged that another useful form of mailer could be produced by incorporating only the adhesive coating 32 embodiment of Figures 17 and 18 without coating 23a, 23b or glue 22a, 22b, 22c, 22d).

24 Adhesive coating 32 may be applied to the standard sheet of paper whilst it is 0 still in roll form either before or after printing. Alternatively, the adhesive coating

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32 may be applied to a standard sheet of paper after it has been cut from a roll O or a larger sheet of paper.

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It will be appreciated that the folding and sealing machine 100 described ,I previously may be adjusted so that it only forms a single fold in the sheet of paper. This is achieved by adjusting the machine 100 so that the second folding plate 12 is bypassed. The machine 100 could thus be used to fold mailers with only two panels. The address details for the first recipient could be 0printed on the second side of one of the panels and the glue would be releasable but not restickable so as to discourage tampering with the mailer.

The glue could also be removable so that it can be easily and cleanly removed for the mailer, for example, by rubbing the glue with ones fingers.

The sheet of paper used to form such two panel mailer may need to be stiffer than what would be used for three panel mailers to satisfy the postal authority's requirements.

Mailers according to embodiments of the present invention are advantageous because they can be formed form a standard sheet of paper. Intermediate forms are not required and thus mailers according to embodiments of the present invention are relatively cheap to manufacture. Additionally, because the mailers are made form a standard sheet of paper, small volumes can readily be manufactured.

All of the various embodiments of the invention are advantageous because adhesive is only ever applied by the folding and sealing machine to one side of the sheet used to form the mailer. This reduces the complexity of the machine required to fold and seal the mailers.

It will be appreciated that a variety of different forms of mailers can be made in accordance with the present invention. More particularly, by varying, for n example, the properties of the adhesive restickable, non-restickable,

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C releasable, non-releasable, degree of adhesion), the positioning of the adhesive

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as applied to the first side of the sheet by the folding and sealing machine, the o use or non-use of coatings, the properties and positioning of coatings and the 0 5 adhesive attraction between the adhesive and coatings it is possible to vary the

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characteristics of the mailer produced. For example, some mailers can be used ,I to forward confidential material through the post to a first recipient in a manner which ensures the information cannot be accidentally viewed by anyone other than the intended recipient. Some mailers are arranged so that it is possible to detect if there has been any tampering with the mailer prior to opening of the mailer by the intended recipient. Other mailers enable confidential material to be securely provided to a first recipient through the post but also include a second recipient's details so that the mailer can be refolded and returned through the post to the second recipient. Some mailers adopt the form of brochures which are not sent through the post and which can be readily opened by the recipient, substantially as if they were a conventional C-fold brochure.

Such brochures may or may not include a mechanism for returning the brochure through the post to a second recipient. Some forms of mailers are posted but are only adhered to the extent necessary for them to meet the postal authority's requirements whilst others are more firmly secured. Some forms of mailers include tear-off strips and/or tear-off panels.

The embodiments have been described by way of example only. Modifications within the spirit and scope of the invention are envisaged.

Claims (32)

1. 2. A method according to claim 1 wherein adhesive is only applied to the first side of the sheet of paper.
2. 3. A method according to claim 1 or claim 2 wherein the information printed on the sheet includes address details of a first recipient or address details for second recipient or address details for both a first and a second recipient.
3. 4. A method according to any one of the preceding claims wherein the adhesive is releasable so that the mailer can be subsequently unfolded without damage to the sheet of paper.
4. 5. A method according to claim 4 wherein the adhesive is reusable so that the sheet can be refolded and adhered using the same adhesive after an initial unfolding.
5. 6. A method according to claim 4 or claim 5 wherein the adhesive is hot melt glue.
6. 7. A method according to any one of the preceding claims wherein the step of folding the standard sheet of paper includes forming two fold lines in the 27 sheet so that a first fold along a first folding line brings a leading end panel into Scontact with a middle panel and a second fold on a second folding line brings a trailing panel into contact with a second side of the leading panel. 0 00 5 8. A method according to claim 7 wherein the adhesive is applied adjacent each of the side edges of the sheet.
7. 9. A method according to claim 8 wherein the adhesive is only applied to the middle and trailing panels of the sheet. A method according to claim 8 or claim 9 wherein the adhesive is also applied at a second location adjacent a trailing edge of the sheet.
8. 11. A method according to any one of claims 9 to 10 wherein the adhesive is also applied at a second location on the middle panel of the sheet.
9. 12. A method according to any one of the preceding claims wherein a coating is applied to zones on the sheet of paper prior to applying the adhesive, the coating and adhesive having properties such that when the coating and adhesive are in contact with one another when the sheet is folded to produce the mailer, the sheet is adhered in a manner consistent with the intended use of the mailer.
10. 13. A method according to claim 12 further including the step of unfolding the sheet so that it opens out flat and then folding the sheet so that the first side of the trailing panel is in contact with the middle panel and then folding the leading panel so that its first side is in contact with the second side of the trailing panel so as to form a retumrn mailer.
11. 14. A method according to claim 13 wherein the coating and adhesive have properties such that when the coating and adhesive are in contact with one another when the sheet is folded to produce the return mailer, the sheet is adhered in a manner consistent with the intended use of the return mailer. 28 O O A method according to claim 13 or claim 14 wherein the coating is O located adjacent the side edges of the sheet. 00
12. 16. A method according to any one of claims 13 to 15 wherein the coating is also applied at a second location on the sheet.
13. 17. A method according to any one of claims 12 to 16 wherein the width of 10 the coating is greater than the width of the adhesive applied to the sheet. O
14. 18. A method according to any one of claims 12 to 17 wherein the coating is applied during the step of printing the standard sheet of paper.
15. 19. A method according to any one of the preceding claims wherein an adhesive coating is applied to the sheet of paper prior to applying the adhesive, the adhesive coating having properties such that when a portion of the adhesive coating makes contact with another portion of the adhesive coating those portions adhere to one another in a manner consistent with the intended use of the mailer, but when a portion of the adhesive coating makes contact with a portion of the sheet without the adhesive coating those portions do not adhere. A method according to claim 19 wherein the adhesive coating is located on the first side of the sheet adjacent the perimeter of the trailing and middle panels.
16. 21. A mailer made in accordance with the method of any one of claims 1 to
17. 22. A mailer including a sheet of paper including a leading edge, a trailing edge, opposed side edges, an imaginary first folding line and an imaginary second folding line, the leading edge and the imaginary first folding line bounding a leading panel, the first and second imaginary folding lines bounding 29 bounding a leading panel, the first and second imaginary folding lines bounding 0 a middle panel and the imaginary second folding line and the trailing edge (N bounding a trailing panel, adhesive applied to the middle and trailing panels of a o first side of the sheet of paper, information for a first recipient applied to the first 0 5 side of the sheet of paper and at least first or second recipient's address detailed applied to a second side of the sheet of paper.
18. 23. A mailer according to claim 22 further including a coating applied to the i first or the second side of the sheet.
19. 24. A mailer according to claim 23 wherein the coating is applied adjacent each of the side edges of the sheet. A mailer according to claim 24 wherein the coating is located on the middle panel on the first side of the sheet and on the leading panel on the second side of the sheet and adhesive is applied to the coating on the middle panel of the sheet.
20. 26. A mailer according to claim 25 wherein the coating and the adhesive on the middle panel extends substantially from the imaginary second folding line.
21. 27. A mailer according to claim 26 wherein adhesive is applied adjacent the side edges of the trailing panel and on top of the coating on the middle panel.
22. 28. A mailer according to claim 27 wherein the coating is also applied at least at a second location on the first side of the middle panel adjacent to the imaginary second folding line and at least at a second location on the second side of the leading panel adjacent the imaginary first folding line.
23. 29. A mailer according to claim 28 wherein adhesive is applied on top of the coating at the second location on the middle panel and at a second location on the trailing panel so that the coating on the second side of the leading panel and the adhesive at the second location on the trailing panel are positioned so that 30 when a fold is made along the imaginary second folding line following making a fold along the imaginary first folding line, the adhesive at the second location on the trailing panel contacts the coating on the second side of the leading panel. 00 5 30. A mailer according to any one of claims 23 to 29 wherein the coating and adhesive having properties such that when the coating and adhesive are in contact with one another when the sheet is folded to produce the mailer, the sheet is adhered in a manner consistent with the intended use of the mailer.
24. 31. A mailer according to claim 30 which can be unfolded so that it opens out flat and then refolded so that the first side of the trailing panel is in contact with the middle panel and the first side of the leading panel is in contact with the second side of the trailing panel so as to form a return mailer.
25. 32. A mailer according to claim 31 wherein the coating and adhesive have properties such that when the coating and adhesive are in contact with one another when the sheet is folded to produce the return mailer, the sheet is adhered in a manner consistent with the intended use of the return mailer.
26. 33. A mailer according to any one of claims 22 to 32 including one or more tear-off portions.
27. 34. A folding and sealing machine for folding a mailer in accordance with the method of any one of claims 1 to A folding and sealing machine including means for feeding a standard sheet of paper into the sealing machine, a first sensor means for detecting the sheet of paper, means for applying glue to the sheet following detection of the sheet by the first sensor means, means for making a first fold in the sheet and means for making a second fold in said sheet.
28. 36. A folding and sealing machine according to claim 35 wherein the means for making the first fold in the sheet and the means for making the -31- second fold in the sheet are each arranged so as to prevent contact with the adhesive applied to the sheet. 0 37. A folding and sealing machine according to claim 35 or claim 36 00 5 further including a second sensor means arranged to detect that the sheet fed into the machine has been received by the first folding means.
29. 38. A folding and sealing machine according to claim 37 arranged so that (if the second sensor means fails to detect that the sheet has been received by S 10 the first folding means within a preset time frame the machine ceases operation.
30. 39. A method of forming a mailer substantially as hereinbefore described with reference to the accompanying drawings.
31. 40. A mailer substantially as hereinbefore described with reference to the accompanying drawings.
32. 41. A folding and sealing machine substantially as hereinbefore described with reference to the accompanying drawings. Dated: 28 October 2005 PHILLIPS ORMONDE FITZPATRICK Attorneys for: dot2dot Post Pty Ltd