AU2010241370A1 - Postage articles - Google Patents

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant(s): Card Tech Pty Ltd Invention Title: POSTAGE ARTICLES The following statement is a full description of this invention, including the best method for performing it known to me/us: - 2 POSTAGE ARTICLES FIELD OF THE INVENTION 5 The present invention relates to postage articles or articles designed to be processed by and sent through the usual postal system using conventional postal services, equipment and installations. 10 In one form, the present invention relates to a postal device or mailing device, such as for example, a mailer for containing an item to be sent through the national postal delivery service, including the usual delivery system for ordinary mail items enclosed within an 15 envelope, particularly using usual domestic mail processing and delivery systems. In one form, the present invention relates to a postal mailer for containing an item in which the item is secured 20 within the mailer by a cover allowing the mailer to be prepared using automated machinery and also to be processed through automatic mail handling machinery without the mailer causing interruption to the smooth operation of such machinery, and/or becoming damaged 25 during processing by automated machinery, including high speed automated machinery. The present invention finds particular application as a postcard or postcard type mailer for transporting an item 30 through the post in a manner in which the item is protected, particularly bulk mail out items which are prepared in vast quantities for mailing to many individuals in a batch, such as in a mailout, marketing 2468552_1 (GHMatters) 11/11/10 -3 campaign, public notification or similar. The construction of the mailer allows a multitude of similar postcards to be prepared and/or processed in a batch using automated handling equipment, and to be treated as a 5 normal piece of mail by the postal delivery service requiring passage through automated mail handling equipment for delivery to an intended recipient without fouling and/or disrupting operation of the automated machinery. 10 Although the present invention will be described with particular reference to one or more embodiments of the postcard mailer and similar, it is to be noted that the scope of the invention is not restricted to the described is embodiment, but rather the scope of the invention is more extensive so as to include other forms and arrangements of the mailer and the use of the various forms of the mailer for purposes other than as specifically described. 20 BACKGROUND OF THE INVENTION Conventional articles of mail usually have an envelope enclosing the contents of the article of mail, such as for example, letters, packages or the like. However, the 25 postage rate for mail articles having an envelope can be greater than the postage rate for postcards which do not require an envelope since generally postcards are lighter in weight than mail in the form of envelopes. When having a large mailout, being able to use postcards for sending 30 out substantially identical items, such as for example, items used as a mailout for a marketing campaign or public notification, provides considerable savings in postage charges because of the lower costs incurred when using 24685521 (GHMatters) 11/11110 - 4 postcards. Therefore, there is an incentive to use postcards to mail information to recipients whenever possible to minimise costs. s However, one of the problems of using a postcard is that the information contained on either surface of the postcard is exposed on the surface or surfaces of the of the postcard, and hence is readily visible to any person coming into contact with the postcard and being able to 10 view the information on the surface or surfaces. Therefore, private and personal information of a confidential or secretive nature cannot be sent through the usual mail delivery service using a postcard despite the lower costs because of the chance that private is confidential information will be disclosed to unauthorised persons. This is particularly so owing to the increasingly stringent privacy laws and regulations. Attempts to use postcards for sending private information have been tried previously by concealing some or all of 20 the information using some form of obscuring panel or device to conceal the sensitive information and to keep the private information secret. However, in the situation where solid items having a thickness are being sent through the post, such as a plastic identification card or 25 other objects no thicker than National Post specifications, the existing methods of obscuring or concealing the information suffer from one or other problem due to the size or thickness of the item. One of the problems is due to the extent that the item attached 30 to the postcard, such as for example, a laminated authorisation card or similar, extends outwardly from the plane of the postcard, i.e. is proud of the postcard surface, or sticks out of the surface, to form a ridge or 2468552_1 (GHMatters) 11/11/10 - 5 edge that can act as an obstruction when the postcard is being processed by the mail handling machinery. When postcards containing the authorisation cards having the ridge or edge are being formed, assembled, packaged and/or 5 are being sent through the mail, the ridge or edge of the card contacts the normal mail handling machinery used in forming the package or processing mail, such as example for franking mail, and/or sorting mail, so that the postcard gets caught in the machinery which disrupts the io smooth operation of the mail forming and/or handling machinery by the ridge or edge of the authorisation card often becoming blocked within, or snagged upon, or otherwise being caught up in the machinery resulting in stoppage of the machinery thereby disrupting the 15 automation, since such machinery is not primarily designed for handling such thick articles and/or articles having a defined edge or ridge. Furthermore, forming or packaging of postcards containing 20 authorisation cards and similar in an automated way is difficult owing to the edge or corner of the card being raised off the surface of the postcard as the postcard moves through the machinery, which in turn increases the chance or incidence of contact of the card with the 25 automated machinery being used in assembling the postcard. This contact which results in the corner or edge of the authorisation card being initially lifted away from the postcard, sometimes followed by the entire card being lifted away from the postcard, with the potential for the 30 card to be dislodged from the postcard and to jam in the machinery thereby disrupting the automated operation of the machinery and the smooth flow of postcards through the machinery. This is particularly so when many thousands of 24685521 (GHMatters) 11/11/10 -6 near identical postcard packages each containing an authorisation card are being formed and assembled and processed repeatedly in a single batch. 5 Merely covering the authorisation card with a label is not sufficient to prevent lifting of an edge or corner of the authorisation card away from the postcard in the machinery used for automated handling of the postcard because the abrupt or defined edge or ridge remains, albeit with a 10 reduced chance of being caught up in the machinery. Therefore, there is a need for a system or arrangement to be developed whereby solid items such as for example, authorisation cards having a thickness can be attached to postcards for delivery by the usual postal system to take 15 advantage of the lower postal charges which system or arrangement does not result in the item interfering with the smooth operation of machinery used in either producing the mailing item, such as the postcard, or in handling or processing of the mail article, such as stamping or 20 franking the postcard prior to delivery or sorting the postcard during delivery to the intended recipient. Accordingly, it is one aim of the present invention to provide a mailing package or arrangement which is able to 25 be used in automated mailing systems, including both automated mail producing or forming machinery, and mail handling machinery. Accordingly, it is an aim of the present invention to 30 provide a postcard or mailer for containing an item, typically a solid item, in which the item is protected from contact with the automated machinery thereby reducing the chances of disruption to the automated machinery being 24685521 (GHMatters) 11/11/10 -7 used to form and process the mailer. Accordingly, it is an aim of the present invention to provide a method of forming a mailer, having the form of a s postcard containing an item for transporting the item through the mailing system in which the item is protected in such a manner to provide a gradual transition from the surface of the postcard to the protruding surface of the item thus allowing smooth passage of the postcard and item 10 through mail handling machinery. SUMMARY OF THE INVENTION According to one aspect of the present invention, there is 15 provided a postal mailer suitable for use in transporting and/or delivering through the postal system an item, said mailer comprising a main body portion forming a substrate of the mailer, the main body portion having an area for receiving the item, a protector or protective layer 20 located in abutting relationship with the item so as to overlie the item when located in or on the area, said protector having at least one part or one surface that is non-stick or releasable for contact with the item, a cover located in abutting relationship with the protector for 25 concealing the item, at least a part of one surface of the cover being provided with an adhesive, an adhesive coating or adhesive layer, wherein the surface of the cover having the adhesive is adhered to the substrate using the adhesive of the cover so as to retain the item in or on 30 the area of the substrate intermediate the protector and the substrate in which the protector overlies the item and the cover is located with respect to the protector, such that the cover and protector are aligned with one another. 2468552_1 (GHMatters) 11/11/10 - 8 A method of forming a mailer for use in transporting an item using the postal service comprising the steps of providing a postal card having a main body portion for s forming a substrate of the mailer, locating an item at a preselected location on one surface of the substrate, applying a protector or protective layer to the item so that the protector or protective layer overlies the item, said protector or protective layer having at least one 10 non-stick surface or at least a non-stick layer for contact with the item, applying a cover or cover layer having at least a part of one surface of the cover provided with an adhesive to the substrate to adhere at least a part of the cover to the substrate to retain the 15 item in place in the preselected position on the substrate intermediate the protector or protective layer, wherein the protector or protective layer overlies the item with the non-stick surface in contact with the item, and the cover and protector are aligned to one another. 20 BRIEF DESCRIPTION OF ASPECTS OF THE INVENTION Typically, the item that can be delivered by or attached to or carried by the mailer is a solid item, more 25 typically a rigid or semi rigid item having a thickness. Typically, the item has a thickness which extends outwardly of the plane of the mailer in a substantially outwards or perpendicular direction. More typically, the item has a thickness greater than the thickness of the 30 postcard so that the item sticks out from the surface of the mailer. Typically, the item includes the following: cards, 24685521 (GHMatters) 11/11/10 -9 identification cards, membership cards, credit cards, authorisation cards, vouchers, tickets, cards of any type or description, keys, key rings, coins, sachets, medals, brooches, medallions, badges, samples, Personal s Identification Numbers (PIN), pins, personal details, personal or private data, promotional items, codes, security codes, passwords, web keys, authorisation information and devices, or the like. Typically, the item is of the type that can be attached to, protected by, 10 encapsulated under a cover, screen, panel, label or the like, on or to a postcard, mailer, carrier or similar. The item includes small integrated generic or personalised items such as advertising, information, gifts, response arrangements, marketing schemes, reply cards, survey 15 cards, corporate gifts, public notification materials, publicity materials, PINS, security information, anti tamper proof information, or similar material of various types that are used in mailouts of a personal or promotional nature, or the like. 20 In one form, the item has personalised information details, data or the like of the recipient or pertaining to the recipient, or about a promotion, event, occasion or similar. In one form, the information on the item is 25 complementary to the information printed on the postcard or mailer. Typically, the item is data matched to the postcard so that the postcard receives the corresponding correct item, such as for example, the name on the postcard is the same as the name on the item. 30 The item is made from paper or paper products, card or cardboard and related products, plastics materials, composite materials, laminated materials, layered 24685521 (GHMatters) 11/11/10 - 10 materials, metals, wood, alloys, composites, including combinations of two or more such materials, or the like. Typically, the item is rectangular, square, oblong, 5 circular, elliptical, disc-like, planar, polygonal or the like. Typically, the item has any shape, form, appearance, function, purpose or similar, and, within reason, has any thickness that can be tolerated by automated mail handling equipment, particularly when the io edges or limits of the item are covered by one or more layers to smooth the edges. Typically, the item is attached to the surface of the substrate by an adhesive, such as for example, a drop or 15 spot or area of adhesive, a tack material, or the like to retain the item in the correct orientation and/or position prior to being enclosed, encapsulated or the like by the protector and/or cover. Typically, the item is retained temporarily for a shorter or longer period of time. 20 However, the item can be merely located on or within the region without the use of additional holding means or elements such as glue, adhesive, tack material or the like, to retain the item in place. 25 Typically, the substrate forming the body of the mailer or mailing device is a postcard. Typically, the postcard is made from card, cardboard, plastics materials, or related products including combinations of two or more materials. The postcard is made from any suitable stock and can be of 30 any suitable thickness. However, typically the weight and/or thickness of the postcard is between about 200 gsm to about 500 gsm for postal requirements. 24685521 (GHMatters) 11111/10 - 11 The stock from which the postcard or mailer may be formed may be of any weight but should preferably be no heavier than 125 grams maximum, inclusive of the attached item, to comply with postal authority requirements, particularly to 5 take advantage of the lower postal charges. The stock of the mailer or postcard is manufactured from recycled, coated, uncoated, treated, untreated board, paper, plastic materials, stock material including 10 combinations of two or more such materials. The postcard or mailer may be made of a single layer of material or two or more layers in the form of a laminated structure, a layered structure or similar. A security device or element can be located on or within the mailer to aid in is maintaining the information being conveyed in the mailer more secure or to assist in tracing the mailer during processing, transportation, delivery or the like. In one form, the postcard is embossed. Typically, the 20 embossing is a depression, cavity or similar, such as a well, trough or similar, in and/or through the thickness of the postcard substrate for receiving at least partially the item in order to reduce the extent at which the item extends outwardly from the surface of the substrate, i.e. 25 stands proud of the surface. More typically, the well has a depth of up to about the thickness of the item so that the item can be received either entirely or partially in or within the well. More typically, the well is located in the region or vicinity of the location of the item, 30 preferably at the preselected location, so that the item has a lower profile when in the well so that the edge or corner of the item is less pronounced and hence forms less of a thickness that can get caught on or jam in the mail 24685521 (GHMatters) 11111/10 - 12 processing machinery. Typically, the depression assists in maintaining the item in the correct location prior to covering, encapsulation 5 or similar by the protector and/or cover. The postcard can be made of any suitable size, preferably having an aspect ratio of length to width of about 1:1.2 in which the length is about 1.2 times the width. 10 Preferably the postcard is within a range of sizes from about 88 x 138 mm to about 130 x 240 mm. In one form, the mailer is a single layer, whereas in other forms, the mailer has two or more layers. In one 15 form, the mailer is a laminate or layered structure in which one or other layers can be separated from another layer or layers. In one form, the postcard is provided with a line of 20 weakness to assist in opening the mailer to retrieve the item. Typically, the line of weakness is a line of perforations. More typically, the line of perforations is in the top layer or on the surface of one face of the substrate of the postcard in the event that the substrate 25 is of a layered construction. More typically, the line of weakness does not extend through the thickness of the postcard. Typically, the line of weakness is on the side of the mailer opposite to the side upon which the item is located so as to allow access to and/or retrieval of the 30 item or mailer from the reverse side of the mailer. In one form, the postcard may be provided with a break line, a score line, a fold line, a hinge line or the like making it possible to gain access to the item, such as 24685521 (GHMatters) 11/11/10 - 13 from the rear of the card, to fold the card, to divide the postcard into segments or the like, such as to form a wallet or other form. s In one form, the protector or protective layer is separate to the cover or cover layer. In another form, the protector or protective layer is combined with the cover or cover layer such as for example, as a two piece or two layer assembly intimately connected together. Typically, 10 the protector or protective layer is a separate layer, piece, sheet, panel, slip, rectangle or the like. In one form, the cover and/or protector can be laser printable or inkjet printable or similar. Any suitable is form of printing or presentation of the postcard is possible or of any component of the mailer. In one form, the protector or protective layer is provided with a line of weakness, typically the line of weakness is 20 a die cut. More typically, the die cut extends partially or entirely through the thickness of the protector or protective layer. Even more typically, the die cut is a continuous loop entirely through the thickness of the material from which the protector is made to define the 25 protector, including its size and shape, and allowing the protector to be easily removed from the remainder of the material from which it is made. In one form, the protector or protective layer is provided 30 with a backing layer or backing sheet, or other support layer, sheet or structure to provide integrity for the protector or protective layer. 24685521 (GHMatters) 11/11110 - 14 In one form, the protector or protective layer is made from paper, plastic or similar flexible or semi-flexible material. In one form, the protector or protective layer has two sides or faces. One or both faces are treated or s are untreated. Different treatments can be applied to different faces. One treatment applied to one face is a release coating, a non-stick coating or the like which prevents, reduces, resists adherence to an adhesive or to the item. 10 In one form, the protector includes a plastic layer applied to one side. In one form, the protector is a dual layer laminate of a paper material as one layer and a release coating as another layer. In one form, the is protector is a single layer, such as a paper layer, to which a release or non-stick coating has been applied to one side, surface, face or the like. In one form, the cover or cover layer is a single layer, 20 dual layer or multiple layer. In one form, one of the outer layers is an adhesive layer. The adhesive layer is a fully adhesive layer, i.e. has an adhesive layer or adhesive coating over the entire surface of one side of the cover. Alternatively, the cover has adhesive either 25 as a separate layer or coating applied to only a part of the surface of one side, such as for example around the edges thereof only, such as for example to form an adhesive border, outline, frame, margin or the like. More typically, the peripheral part of one surface is provided 30 with adhesive for contact with one surface of the substrate of the postcard to envelope, surround, encapsulate the item within the cover or cover layer. 24685521 (GHMatters) 11/11 /10 - 15 In one form, the adhesive where located, is continuous whereas in another form, the adhesive is discontinuous being arranged in separate discrete spaced apart locations either in regularly repeating patterns or randomly. 5 Typically, the cover is die cut, more typically, die cut so as to not penetrate the thickness of the cover or cover layer. More typically, the cover has a line of weakness, such as for example, a line of perforations, preferably an 10 endless line or loop of spaced apart perforations. More typically, the perforated line divides the cover into an inner panel and border area or margin area. Even more typically, the size of the inner panel of the cover or cover layer corresponds more or less exactly to the size is of the protector or protective layer and is superposed on the protector or protective layer. In one form, the location of the cover or cover layer is an alignment or in register with the protector or protective layer so that both the cover and protector encapsulate, enclose, 20 envelope, surround, contain or the like, the item between them and the substrate of the mailer such as in a sandwich-like construction in which the cover and substrate of the mailer form the outer layers and the item forms the core of the structure. 25 In one form, the line of perforation allows the cover to be removed from the substrate thereby allowing the item to be retrieved from the mailer. 30 Typically, the cover has a second cut, typically a die cut, more typically, a continuous line or loop of die cut through the entire thickness of the cover to define the size and shape of the cover. Typically, the size of the 24685521 (GHMatters) 11/11110 - 16 cover is larger than the size of the protector. More typically, the two die cuts, being the perforation line and the cut line defining the size and shape of the cover, are formed from the one side of the cover. Even more 5 typically, the two die cuts are formed simultaneously. In one form, the die cut/perforation of the protector is on one side and the die cut of the cover is on the other side, typically, the opposite side. 10 Typically, the cover/protector layer combination is die cut on one side, typically, the inner side, to the desired size inclusive of the area to cover the encapsulated item, plastic card or the like, and an extended edge portion in 15 the form of an outer border to adhere the cover, and optionally, the protector, to the postcard around the edges of the cover. The reverse of the cover/protector layer combination is die cut, typically the outer side, to correspond to about the size of the item so as to overlie 20 the item and protect the item from contact with the adhesive. In one form, the encapsulation process of applying the protector/cover over the.item can be done manually or with 25 label application machinery of the type that is fully automated. In one form, the cover and/or protector is transparent, semi transparent, translucent, opaque, or has any suitable 30 surface treatment to conceal or obscure information on the item. In one form, there is a tie layer, coupling layer, bonding 24685521 (GHMatters) 11/11/10 - 17 layer, intermediate layer or the like between the cover and the protector, or within the cover layers or within the protective layers to assist in bonding the individual layers together. 5 In one form, the mailer and/or protector and/or cover is provided with anti-tamper or tamper evident security type devices. In one form, the device includes security type cuts to their edges so as to make it very difficult to 10 remove the protector and/or cover without destroying the mailer or making it evident that there has been tampering or an attempt at tampering or that the item has been interfered with or removed or replaced or substituted without authorisation. 15 BRIEF DESCRIPTION OF THE DRAWINGS One embodiment of the postcard mailer will now be described by way of non-limiting example with reference to 20 the accompanying drawings in which: Figure 1 is a front perspective view of the assembled postcard prior to mailing; 25 Figure 2 is a cross-sectional view through 2-2 of Figure 1; Figure 3 is an enlarged view of circle A of Figure 2 showing the cross-sectional arrangement in more detail; 30 Figure 4 is a perspective view of one form of the cover used in the present invention showing the die cut outline and line of perforations; 24685521 (GHMatters) 11/11/10 - 18 Figure 5 is a schematic side elevation and plan view of the formation of one form of the protector; s Figure 6 is a schematic side elevation and plan view of the formation of one form of the cover; and Figure 7 is a perspective view of the mailer in an opened configuration showing removal of a card from the mailer. 10 DETAILED DESCRIPTION OF A SPECIFIC EMBODIMENT One embodiment of the postcard mailer will now be described. 15 In the drawings, there is shown one embodiment of the mailer in the form of a postcard, generally denoted as 10. Postcard mailer 10 has a mailer body portion or substrate 12 forming the main supporting structure or backbone of 20 the mailer and conferring rigidity, form, and/or strength to the mailer with sufficient thickness, integrity and stiffness to enable the mailer to be sent through the normal postal service as an entire structure for delivery as an article of mail whilst still maintaining its 25 integrity. Accordingly, mailer 10 is provided with an area for receiving a postage stamp or equivalent, such as a "postage paid" or "reply post free" endorsement or the like. A further area is provided on the same surface of the mailer as the postage stamp area for indicating the 30 details of the recipient, such as the name and address to which the mailer is to be delivered. The stamp receiving area and address details area may be on the same side as the item or may be on a different side of the postcard to 24685521 (GHMatters) 1111/V10 - 19 the item, or the two areas may be on different sides to one another. In one form, the name and address are provided on a separate label, typically, a pre-printed or previously printed label, such as a stick-on label that 5 can be adhered directly or indirectly to the surface of the mailer in a convenient or preselected location whereas in another form, the name and address details are printed directly onto the mailer, such as by a printer, including a laser printer, an inkjet printer, or the like. The 10 address details label may take any suitable form or be of any suitable type. The address label may be different from or incorporated into the other parts of postcard 10, such as the cover and/or protector. In one form, the label may be adhered to the cover or the cover may be 15 printed with the address details. Substrate 12 can be made from any suitable material, such as for example, cardboard, card, or similar. Additionally, substrate 12 can be of any shape or size. 20 However, it is preferred that the shape be rectangular and that the size, as well as the weight conform to postal regulations so as to attract as low a postal charge as is possible. 25 The reverse face or side of substrate 12 is the face or surface on which the item being delivered to the recipient via the mailer is retained. In one form, there is a region 22 which is designated to be the region within or upon which the item is located. Region 22 may be provided 30 with a suitable indicator as to the location and size of the region. In one form, the region is printed in a complementary or contrasting print, such as for example, being a different colour, print style, font or similar, or 24685521 (GHMatters) 11/11/10 - 20 by providing an outline, a border or other identifying marking or indicia to denote area or region 22. In another embodiment, there is an embossing in the form of a recess or a depression or similar. In one form, the s recess or depression is in the form of an open well, (not shown), for receiving the item therein and also to assist in locating the item during subsequent formation of the mailer, particularly during the application of the protector and/or cover, and optionally, and to a lesser 10 extent during processing and delivery of the mailer. An item to be delivered via the mailer is located upon or in the identifying region 22, including in the well if provided. The item can take any suitable form or be of is any suitable type. In one form, the item is an identity card or membership card 32, such as for example, a card made from paper, card, cardboard, plastics materials or similar including combinations of different or similar materials. The card may be a credit card, a membership 20 card, an identification card, authorisation card or the like. Additionally, the card may be a voucher, ticket, label, or similar. It is to be noted that the card item 32 has a thickness, such as for example, is of a thickness thicker than a sheet of paper or the like so that when 25 located on the reverse face of substrate 12, the edges or corners of the card are exposed forming edges, ridges or the like formed by the edge of the card being above the level of the plane of the surface of the mailer. Card 32 stands proud by projecting outwardly, typically 30 perpendicularly outwardly from the surface of substrate 12. Item 32 can also take the form of a different shape, such as for example, a key, or other solid or rigid object, particularly a substantially planar solid object 24685521 (GHMatters) 11111110 - 21 such as for example, a token, coin, medal, badge, medallion, or similar planar object, particularly in the form of a disc or other circular substantially planar shape. Optionally, in some embodiments, substrate 12 is 5 provided with a depression or similar, such as a well of complementary shape to that of the item, for receiving item 32 wholly or partially therein to lower the profile of item 32 thereby reducing the height of the exposed edge or ridge, thereby assisting processing of the mailer with 10 a reduced chance of the mailer disrupting the smooth operation of the mail processing machinery by becoming jammed in the machinery. The present embodiment will be described with reference to a card denoted as 32, for ease of description. 15 A protector or protective layer 42, is located to overlie card 32 when located on or in region 22 of the reverse face of mailer 10. The main purpose of protector 42 is to overlie card 32 and to smooth the abrupt edges or ridges 20 formed by the edges or corner of the card. In one form, protector 42 covers card 32 and extends beyond the perimeter of card 32 including the edges and/or corners of card 32. Protector 42 has two faces which are firstly, an inwardly directed face 44 or an inner face, which is in 25 abutting contact with the outer face or outwardly facing surface of card 32, and secondly an outwardly directed face 46 facing away from card 32 in the direction of protector 42. 30 It is to be noted that protector 42, such as for example, in the form of a layer, is superposed over card 32 so as to overlie the outwardly directed face of card 32 and also to extend beyond the edges, corners, borders, or 2468552_1 (GHMatters) 11/11/10 - 22 boundaries of card 32 so as to fully overlie card 32 to assist in covering, and hence smoothing the edges or ridges formed by the corners or edges of card 32 when located on mailer 10 as shown more particularly in Figures 5 2 and 3. Protector 42 in one form, is made up of two layers of material, one layer being a treated layer and the other layer being a carrier layer. Outwardly directed face 46 of protector 42 forms or is a treated surface 48, such as either being a non-stick surface layer or coating, 10 or is provided with a non-stick surface layer or coating depending upon whether it is a single layer of material having a surface treatment or a separate layer applied to another layer. Alternatively, outer layer 48 is a release surface layer or a releasable surface, including a release 15 coating. In one example, protector 42 is provided with a suitable plastic coating, release coating or the like or outer layer 48. Further, it is to be noted that the inner layer forming the inner surface 44 or carrier layer 50, is a non-stick surface or a releasable surface or is an 20 untreated or uncoated surface. In one form, inner layer 50 is a paper layer. Protector 42 is made from any suitable material or combination of materials including layers of different 25 materials arranged in a laminate or composite arrangement. Typically, protector 42 is a sheet or panel of paper which is treated on one side which in use is the upper surface 46 and untreated or uncoated on lower surface 44. 30 In one form, protector 42 is provided as part of a sheet of individual identical panels or as a roll of individual identical panels delimited from the remaining material from which the protector is made, such as for example in 24685521 (GHMatters) 11/11/10 - 23 the form of a web or similar. Protector 42 can be selectively removed from the remainder of material by separating the protector and remainder of material from each other as required for use to superpose protector 42 5 upon card 32 as required. Protector 42 can have any thickness that is suitable to be located over card 32 to protect card 32, whilst still allowing mailer 10 to be handled by conventional mail io handling material. In one form, protector 42 is formed by a cutting process, such as for example by being die cut on or from one direction or side of protector 42 on one side surface. In is one embodiment, the die cut is formed from the untreated side 44 or untreated layer 50 of protector 42. In one form protector 42 is stamped or die cut from an elongate strip of suitable material to form a multitude of protectors in spaced apart relationship to one another 20 along the length of material from which they are cut. In one form, there is a single die cut in the form of a continuous loop, the size of which determines the size of the protector or protector layer. The loop is 25 substantially rectangular with rounded corners. Other shapes are possible including square, and the like. Cover 52 is provided to overlie protector 42 and thus form the outer layer of the covering of card 32 enveloping end 30 32 to mailer 10. Cover 52 is of a size greater than the size of protector 42 so that there is a border or marginal region around the edge or perimeter of cover 52 immediately outside the edge or sides of protector 42. 24685521 (GHMatters) 11/11/10 - 24 In one form, cover 52 comprises two layers, inner layer 54 and outer layer 58. Inner layer 54 may be formed as a separate layer or may be formed as a coating applied to a 5 single layer or to the inner surface 54 to form the inner face 56 of cover 52. Outer layer 58 may be formed as a separate layer or as a coating applied to the outer surface 60 of cover 52. 10 In one form, cover 52 is formed with an inner panel or inner portion 62 and an outer border, marginal portion, or peripheral portion or outline 64. A line of weakness in the form of a multitude of perforations 66 in a line is provided to divide the inner panel 62 and outer border 64. 15 Perforations 66 extend around and are spaced from the edge of border 64 to divide cover 52 into inner panel 62 and outer border 64 thereby allowing separation of the inner panel and outer border as required, such as for example, allowing access through cover 52 to gain access to card 32 20 when removing card 32 from mailer 10 after delivery of the mailer to the intended recipient. In one form, inner surface 56 or inner layer 54 is an adhesive layer or adhesive coating applied to one side of 25 cover 52. In one form, the adhesive layer is applied to the entire inner surface of cover 52 including the entire surface of inner panel 58 as well as the entire surface of outer border 64. In use, the adhesive layer of outer border 64 contacts substrate surface 12 of mailer 10 30 around the edge of region 22 and/or edge of card 32 to encapsulate card 32 by the adhesive on the outer border adhering directly to substrate 12 to encapsulate card 32 and protector 42 located intermediate substrate 12 and 2468552_1 (GHMatters) 11/11/10 - 25 cover 52. In one form, cover 52 is provided as a multitude of identical individual pieces located in linear spaced apart 5 relationship to one another along a strip of a suitable backing sheet or web formed from the same material as cover 52 such as carrier layer 58. With particular reference to Figure 6, in one form, cover 10 52 is formed from a sheet or strip of identical panels in the form of a roll 80 of paper having one side coated with adhesive, by applying a first cut to the paper, such as a die cut, to cut cover 52 from the surrounding material. The die cut is a continuous loop, preferably in the form is of a rectangle with rounded corners. The web material remaining between individual covers 52 and alongside the individual covers is waste material and is removed from the web or roll to form covers 52m preferably immediately before cover 52 is used. 20 A second cut is applied to cover 52. The second cut is applied simultaneously with the first cut or the two cuts are applied sequentially, one after the other. 25 The first cut forms the shape of cover 52 whereas the second cut forms a line of perforations 66 on cover 52, such as for example, the line of perforations facilitating removal of card 32 from mailer 10. The two cuts forming the shape or over 52 are applied to the same side of the 30 paper strip to form cover 52 which is preferably the outer side of outer surface of cover 52. In one form, protector 42 and cover 52 are separate from 24685521 (GHMatters) 11/111/10 - 26 each other. In another form, protector 42 is a protective layer adhered to cover 52 so as to form an integrated assembly in which the protective layer and cover are in adhered face-to-face relationship to one another. s In one form, cover 52 is a single layer, a dual layer, or a multiple layer. Cover 52 can be made from a single material or a combination of two or more different materials. 10 In one form, the multitude of covers 52 are removed from the remaining waste material and adhered to protector 42 to form a combined cover and protector as an integral device which can be applied to substrate 12 as an is integrated combination in a single step to encapsulate card 32 to substrate 12 in a single step. Manufacture of one form of mailer 10 will now be described with particular reference to Figures 4 to 6 showing one 20 form of making the protector, one form of making the cover and one form of the combination of protector and cover. Substrate 12 forming the body of mailer 10 is printed on one or both sides with the required information including printing of the postage stamp region, the address region 25 and the like including advertising information, and any other instructions or indicia to be carried or printed on mailer 10. Substrate 12 is located in a desired orientation of the production line with the reverse side of the postcard facing upwards for receiving card 32 in 30 region 22. In one form, cards 32 are stacked in a hopper or similar container in stacked relationship to one another for delivery one card at a time as required in sequence as the substrate passes underneath. 24685521 (GHMatters) 11111/10 - 27 Alternatively, cards 32 are arranged in a linear separated relationship and are mounted for transporting individual cards towards substrates 12 and located on substrate 12 as required. The speeds of movement of cards 32 and 5 substrates 12 are controlled so that one card 32 is placed upon each substrate in turn at the preselected locations. Additionally, mailer 10 and card 32 are data matched to ensure the correct card is located on the correct mailer such as for example, the names and the addresses appearing 10 on the mailer are the same as the names and addresses appearing on the authorised card so that both sets match one another. Any suitable data matching equipment may be used to accomplish this. 15 Meanwhile, protector 42 is being formed as illustrated particularly with reference to Figure 5. Roll 70 of suitable material, such as a strip of paper 72 having a release coating on one side, is provided and unwound along a suitable support, such as for example, bed 74 of a 20 table, cutter support or similar. A movable cutting tool, in the form of a reciprocating die cutter 66 is positioned above bed 74, providing support for and a reaction surface against cutter 76, to cut the strip of material. As strip of material 72 passes under cutter 76 with the paper 25 surface i.e. the surface which does not have or is not the release surface oriented in a direction facing the cutter, cutter 76 reciprocatingly moves to cut a suitable shape to form the outline of protector 42 in the strip of paper. It is to be noted that protectors 42 are arranged in 30 linear spaced apart relationships along the length of the paper strip surrounded by waste material 78 as shown in Figure 5. 2468552_1 (GHMatters) 11/11110 - 28 Simultaneously, cover 52 is being made as illustrated more particularly in Figure 6. Roll 80 of suitable material, such as for example, a length of paper 82 having an adhesive coating on one side is unwound along a suitable s support, such as for example, a bed 84 of a table, support of the like. A movable cutting tool, in the form of a reciprocating die cutter 86 is positioned above bed 84, to cut the material into suitable shapes. As strip of material 82 passes beneath cutter 86 with the paper 10 surface not having the adhesive layer facing the cutter, cutter 86 moves to contact the strip of material to cut the material into suitable shapes forming the cover. Additionally, the cutter is provided with two blades, the first blade arranged and shaped to cut the shape of the 15 cover, and the second blade arranged and shaped to form the continuous line of perforations 66 so as to form a multitude of linearly spaced apart covers 52 extending along the strip of material. Waste material 88 surrounds covers 52 which waste material is removed when cover 52 is 20 to be used. In one form, a removable layer (not shown) is provided against the adhesive layer to allow the covers 52 to be formed without interfering with the manufacturing process so as by the adhesive inadvertently contacting parts of the cutter and/or blade. 25 The combined protector and cover, is formed by separating individual covers 52 from the remainder of material 88 and locating individual covers 52 on the strip of material having protectors 42 in register with the location of the 30 protectors so that the covers are located in alignment with corresponding protectors with the adhesive surface of the cover in contact with the release coating of the protector to form a single combined device. 2468552_1 (GHMatters) 11/11/10 - 29 When the combined protector and cover is to be placed over card 32 and substrate 12, the strip of material containing the protector and cover adhered to each other to form a s combined assembly of both is brought close to substrate 12 and the combined protector/cover is peeled away from the strip containing them in linear spaced apart location thereby exposing the adhesive layer around the border 64 of cover 52 whereupon the combined protector/cover is 10 placed on substrate 12 in alignment with region 22 so that the adhesive border contacts the perimeter of region 22 to envelope the item located on or within region 22 intermediate substrate 12 and the cover/protector combined assembly. 15 In one embodiment, (not shown) the combined protector/cover devices are in the form of a roll containing individual combinations or pairs of protector and covers in linear spaced apart relationship to one 20 another, the combination is arranged so that each combination comprises a protector and cover in aligned face to face relationship with each other adhered together with an adhesive layer or coating sandwiched between the protector and the cover. The pair is separated from the 25 remaining material around the cut line in the material defining the protector 42 which is of a size that is less than the size of cover 52 so that the border of the cover does not overlie the protector but rather leaves a peripheral edge portion having a layer or coating of 30 adhesive exposed on the face of the cover facing the protector. With the non release surface of the protector facing towards card 32, the combination is oriented so that the protector directly overlies card 32 with the 24685521 (GHMatters) 11/11/10 - 30 adhesive border of the inward facing surface of the cover oriented around the edges of the card so that the adhesive borders contact directly the face of the substrate to adhere cover 52 directly to substrate 12 thereby s enveloping card 32 and protector 42 therebetween in a sandwich like construction. As outwardly facing surface of protector 42 remains adhered to inwardly facing surface of cover 52, inwardly facing surface of protector 42 contacts card 32 to prevent the adhesive on the surface of 10 cover 52 from contacting card 32 thereby ensuring card 32 is free from adhesive or is not adhered directly to substrate 12 or any part of mailer 10 so that card 32 can be readily removed from mailer 10 as required when delivered to the recipient. 15 When mailer 10 is delivered to the intended recipient and it is required to remove card 32 from mailer 10, cover 52 can be separated along perforated line of weakness 66 thereby allowing the inner panel of cover 52 to be removed 20 from mailer 10 by tearing along the perforated line to reveal card 32. As protector 42 is adhered to inner surface of cover 52, protector 42 is also removed from the surface of card 32 when the inner panel of cover 52 is removed, thus exposing card 32 and allowing release of 25 card 32 from mailer 10. It is to be noted that adhesive peripheral portion of cover 52 remains adhered to substrate 12. Further it is to be noted that the size of cover 52 is greater than the 30 size of protector 42 by a margin which corresponds to the size of the outer peripheral border portion. 24685521 (GHMatters) 11/11110 - 31 ADVANTAGES OF THE INVENTION Some of the advantages of products made in accordance with embodiments of the mailer described herein include the 5 following: - A discounted postage rate is available by using the postcard mailer for the delivery and processing of such postcards containing the items which are to be 10 sent to the recipient since the lower postage rates associated with postcards are applicable to the mailer. - No envelope is required. - No enclosed letter, instructions or information is is required. - No folding process is required. - No insertion process is required. - Existing machinery can be used for all processing and assembly stages, as well as sorting and delivery 20 processes. - Many of the component parts of the postcard assembly can be made by existing manufacturing process machinery. - The items forming the content of the mailer can be 25 readily released and removed from the postcard by the recipient. - The mailer is useful for containing a wide variety of different items and hence is versatile in forwarding a range of different items of varying sizes, shapes, 30 configurations and types. - The package is tamper resistant in that any release is obvious making unidentified interference with the inserted item very difficult. 2468552_1 (GHMatters) 1111/10 - 32 - The inserted item is protected from damage. - The inserted item can be obscured if required. - The inserted item can be visible if required. - The assembled postcard can be processed by existing s Post Office equipment. - The mailer can be branded and personalised. - The postcard can be used as an advertising medium. - The insert can be personalised, numbered or be branded as required, or can contain standard or variable 10 information. Some embodiments have other advantages. It is to be noted that not all embodiments of the mailer 15 will have all of the advantages indicated above. Some embodiments will have some advantages whilst other embodiment will have other advantages. The described arrangement has been advanced by explanation 20 and many modifications may be made without departing from the spirit and scope of the invention which includes every novel feature and novel combination of features herein disclosed. 25 Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit 30 and scope. 24685521 (GHMatters) 11/11/10

Claims (35)

1. A postal mailer suitable for use in transporting and/or delivering an item through the postal system, s said mailer comprising a main body portion forming a substrate of the mailer, the main body portion having an area for receiving the item, a protector or protective layer located in abutting relationship with the item so as to overlie the item when located 10 in or on the area, said protector having at least one part or one surface that is non-stick or releasable for contact with the item, so as not to adhere permanently to the item, a cover located in abutting relationship with the protector for concealing the 15 item, at least a part of one surface of the cover being provided with an adhesive, an adhesive coating or adhesive layer, wherein the surface of the cover having the adhesive is adhered to the substrate using the adhesive of the cover so as to retain the item in 20 or on the area of the substrate intermediate the protector and the substrate in which the protector overlies the item and the cover overlies the protector, such that the cover and protector are aligned with one another. 25

2. A method of forming a mailer for use in transporting an item using the postal service comprising the steps of providing a postal card having a main body portion for forming a substrate of the mailer, locating an 30 item at a preselected location on one surface of the substrate, applying a protector or protective layer to the item so that the protector or protective layer overlies the item, said protector or protective layer 24685521 (GHMatters) 11/11/10 - 34 having at least one non-stick surface or release surface, or at least a non-stick layer for contact with the item so that the item is not permanently adhered to the protector, applying a cover or cover s layer having at least a part of one surface of the cover provided with an adhesive to the substrate to adhere the least part of the cover having the adhesive to the substrate to retain the item in place in the preselected position on the substrate 10 intermediate the protector or protective layer, wherein the protector or protective layer overlies the item with the non-stick surface in contact with the item, and the cover overlies the protector so that the protector and cover are aligned to one 15 another.

3. A mailer or method according to any preceding claim in which the item has a thickness greater than the thickness of the postcard forming the mailer. 20

4. A mailer or method according to any preceding claim in which the item includes cards, identification cards, membership cards, credit cards, authorisation cards, vouchers, tickets, labels, keys, key rings, 25 coins, sachets, medals, brooches, medallions, badges, samples, personal information, personal identification numbers, security information, anti tamper proof information, promotional items, publicity material, codes, security codes, passwords, 30 web keys or similar.

5. A mailer or method according to any preceding claim in which the item is made from paper or paper 24685521 (GHMatters) 11/11/10 - 35 products, card or cardboard and related products, plastics materials, composite materials, laminated materials, layered materials, metals, wood, alloys, composites, including combinations of two or more 5 such materials.

6. A mailer or method according to any preceding claim in which the item is attached to the surface of the substrate by an adhesive, including a spot or drop of 10 adhesive, a tack material or similar.

7. A mailer or method according to any preceding claim in which the mailer is a postcard having a thickness or weight of between about 200 gsm to about 500 gsm. 15

8. A mailer or method according to any preceding claim in which the postcard is embossed, or is in the form of a depression, cavity, well, trough or the like for receiving at least partially the item within or in 20 the depression, in order to reduce the amount that the item extends outwardly from the surface of the substrate, particularly the height of the edge or corner of the item extending from the mailer. 25

9. A mailer or method according to any preceding claim in which the shape of the depression corresponds to the shape of the item so that the item can be received either entirely or substantially entirely within the depression to assist in retaining the item 30 on or in the mailer.

10. A mailer or method according to any preceding claim in which the postcard is provided with a line of 24685521 (GHMatters) 11/11/10 - 36 weakness to insist in opening the mailer to retrieve the item from the mailer in which the line of weakness is typically in the form of a line of perforations. 5

11. A mailer or method according to any preceding claim in which the line of weakness is on the side of the mailer opposite to the side upon which the item is located so as to allow access to and/or the retrieval 10 of the item or mailer from the reverse side of the mailer.

12. A mailer or method according to any preceding claim in which the protector or protective layer and the 15 cover or cover layer are formed as a combined assembly in which the protective layer and cover layer are intimately connected together to form a single assembly. 20

13. A mailer or method according to any preceding claim in which the protector or protective layer is provided with a line of weakness, typically a line of weakness formed by a die cut which extends partially or entirely though the thickness of the protector or 25 protective layer.

14. A mailer or method according to any preceding claim in which the protector or protective layer is provided with a backing layer, backing sheet, support 30 layer, support sheet, support structure or similar to provide a carrier for, or to reinforce or to provide integrity for the protector or protective layer. 24685521 (GHMatters) 11/11/10 - 37

15. A mailer or method according to any preceding claim in which one side or one surface of the protector or protective layer is a treated surface or layer in which the treatment of the layer or surface is a s release coating, a non-stick coating, or an area which has an absence of adhesive for preventing, reducing, resisting adherence of the protective layer to the item when the item is located in the mailer and the protective layer is in place over the item. 10

16. A mailer or method according to any preceding claim in which the protector or protective layer includes a layer made from paper, plastic or similar flexible or semi-flexible material or is a dual layer laminate of is a paper, plastic or similar material in which one layer is provided with a release coating applied to the surface of the paper as another layer.

17. A mailer or method according to any preceding claim 20 in which the cover or cover layer is a single layer, dual layer or multiple layer in which one of the layers, being the outer layers is provided at least partially with an adhesive layer. 25

18. A mailer or method according to any preceding claim in which the mailer in which an adhesive or adhesive layer is applied round the edges of the mailer in the vicinity of where the item is to be located, including the peripheral edges of the cover to form 30 an adhesive border, outline, frame, margin or similar. 2468552_1 (GHMatters) 11/11/10 - 38

19. A mailer or method according to any preceding claim in which the cover is die cut so as not to penetrate the thickness of the cover or cover layer. 5

20. A mailer or method according to any preceding claim in which the cover is provided with a line of weakness such as, a line of perforations, dividing the cover into an inner panel and an outer border area or margin area. 10

21. A mailer or method according to any preceding claim in which the size of the inner panel of the cover or cover layer corresponds more or less to the size of the protector or protective layer and the cover layer 15 is generally superposed upon the protector or protective layer.

22. A mailer or method according to any preceding claim in which the location of the cover or cover layer is 20 in alignment with, or in register with the location of the protector or protective layer so that the cover and protector match one another to enclose, envelop, surround or contain the item between the substrate and the combined protector and cover. 25

23. A mailer or method according to any preceding claim in which the cover is provided with a second cut in the form of a die cut to form the shape and size of the protector wherein the shape and size of the cover 30 is greater than the shape and size of the protector so that the cover extends beyond the boundaries or edges of the protector. 24685521 (GHMatters) 11/11110 - 39

24. A mailer or method according to any preceding claim in which the two die cuts for forming the cover or cover layer are formed simultaneously. 5

25. A mailer or method according to any preceding claim in which the die cut/perforation of the protector is on one side of the protector, and the die cut of the cover is on the other side of the cover when the protector and cover are in face-to-face relationship 10 with each other.

26. A mailer or method according to any preceding claim in which the mailer is provided with an additional layer in the form of a tie layer, coupling layer, 15 bonding layer, intermediate layer or similar located intermediate the cover and the protector to assist in bonding the cover and protector to one another or to the substrate. 20

27. A mailer or method according to any preceding claim in which the mailer and/or protector and/or cover is provided with an anti-tamper or tamper evident security type device for use in determining whether attempts have been made for unauthorised use of the 25 item, or unauthorised removal of the item from the mailer.

28. A mailer or method according to any preceding claim in which the cover comprises a multitude of identical 30 individual panels located in linear spaced apart relationship to one another along a strip of a suitable backing sheet or web. 24685521 (GHMatters) 11/11/10 - 40

29. A mailer or method according to any preceding claim in which the cover is formed from a sheet or strip of identical panels in the form of a roll having one side of the material forming the roll coated with an 5 adhesive wherein the cover is formed by applying a first cut to the material including using a die cut to form the cover followed by a second cut which is applied simultaneously with the first cut to form a line of perforations on the cover, said perforations 10 for facilitating removal of the item from the mailer.

30. A mailer or method according to any preceding claim in which the two cuts for forming the shape of the cover are applied to the same side of the material 15 from which the cover is made so as to form the cover.

31. A mailer or method according to any preceding claim in which the protector and cover are separate from each other. 20

32. A mailer or method according to any preceding claim in which the protector and cover form a combined assembly in which the protector is a protective layer and the cover is a cover layer in which the 25 protective layer and the cover layer are adhered to one another in face-to-face relationship.

33. A postal mailer suitable for transport and/or delivery through the postal system to forward an item 30 through the mail system in accordance with the present invention substantially as herein described with reference to the accompanying drawings. 24685521 (GHMatters) 11/11/10 - 41

34. A method of forming a mailer for use in transporting an item using the postal service in accordance with the present invention substantially as herein described with reference to the accompanying 5 drawings.

35. Every novel feature as hereinbefore disclosed or defined in the specification and/or drawings when taken alone or in combination with any other feature 10 including features that are novel or otherwise, including groups of two or more features. 24685521 (GHMatters) 11/11110