CA2115011A1 - V-fold with built in reply envelope - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

A mailer type business form is formed from an intermediate made using a first large quadrate sheet of paper and a second much smaller quadrate sheet. A fold line divides the intermediate into first and second equal size panels, the second panel having a cut out window and the first panel having a second sheet placed over a portion thereof to form a return envelope. A reply address is printed on the second sheet at a portion thereof in alignment with the cut out window when the first sheet is V-folded about the fold line. A
repositional adhesive label is applied over the reply address, and the mailer is sealed with adhesive along the edges of the second panel. The mailer is manufactured with a minimum number of operations in a relatively simple manner.

Description

V-FOLD ~IT~_BUILT_IN REP _ ENVELOPE .~
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BACKGROUND ~ ~DMflAR~ Cr~ INVENTION .

Mailers are a popular type of business form. It is :
often desirable for a mailer to be able to convey a great ...
deal of confidential information, while providing a reply envelope to allow the recipient of the mailer to mail :~
order forms, ~uestionnaires, or like documents back to the original sender of the mailer.
United States patent 4,706,877 shows a particular type of mailer that is constructed with ~ built in return Pnvelope that is very easy to use. The bllilt in return envelope includes a repositional label which covers a . ;.
reply address on the reply envelope part of the mailer. ;~
The repositional label has the outgoing addressee :~
information printed thereon and is visible through a :
window in a covering ply. Once the mailer i5 opened by ~::
the recipient, the repositiona]. label can be removed from ::.
its position covering the reply ~ddress and placed on the return address portion of tl-e reply envelope. .
While the mailer of U S. patent 4,7n~,877 is advantageous, it has a few drawhacks thereto, and is constructed in a manner that is not as simple as desired.
The mailer of the 4,706,877.patent uses sheets that are run~rom the same size press so that two continuous webs are glued together to form a ret-lrn enve].ope, which must be of a predetermined size. In contrast to such a construction, accorjding to the present invention the ! ' return envelope can be of various sizes, and is made of a second sheet of paper having di.mensions much less than one of the panels of a first sheet of paper, so as to minimize paper waste. The mailer produced according to the invention al80 is easier to open because there is only a .
small portion where there are three plies, rather than three plies all around all three openable sides as in the 4,706,877 construction. Also, the mailer according to the -., ~
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present invention allows more r~om for internal indicia, and may be produced merely ~Ising a press, "85" machine, and Labelaire~ machine, that is not reguiring a collator such as is typically utili7ed in the con~truction of a mailer such as in U.S. Patent No. 4,706,~77.
The invention comprises an intermed;~te for forming a mailer, a mailer so formed, and a method of manufacture of ;;~;~
a mailer. The mailer that i~ produced a~oording to the present invention has a large ~mount of interior space for printing of confidential i.nformation, is ~sy t~ open, and provides an easy to use retllrn envelope. ~ h~
According to one aspect of the pre~nt invention an intermediate for a mailer type husiness ~orm is provided.
~he intermediate comprises the following ~lements: A
first generally quadrate 6heet of paper h~ving parallel first and second edges, and par~llel third and fourth edges perpendicular to the fir~t and sec~nd edges. A fold line substantially bisecting the third ~nd fourth edges and parallel to the first and ~econd edg~, defining first ;~
and second panels. Means rr~v;ding a Cllt O-lt window in the second panel. A reply ~nv~lope forming quadrate --~-second sheet having dimen~ b~tanti~l1y less than the dimensions of the first sh~et. ~ first ~ esive pattern. ~ i connecting the second shee1-. t.o t:l~e first ~7~eet first panel to form a reply envelope. ~ply addre~ ;ndicia printed on the second sheet at a po.rtl~l- thereof in alignment with the cut out window when the fil~t sheet i~ V-folded about the fold line. A repositional ~dhesive l~hel applied to the second sheet covering t.hP r~ly addr~s~, and having an outgoing address thereon. ~ second adh~sive pattern!for connecting the first panel to tl~e secon~ ranal along the ~:~
edges thereof when V-folded abollt the fold line. And, lines of weaknesæ formed in the first an~ ~econd panels adjacent the edges of the first sheet for allowing ready ~ ~-opening of a mailer formed by V-folding ~bout the fold ~ -line and adhesive attachment by the second adhesive.
The reply address is preferably in a readable line, . -~
which i~ parallel to the fold line. The return envelope , ,, , .:
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has a flap with rewettable ~h~i.v~, an~ connected at a top portion thereof by a lil~e of weakne~.c foxmed in both .
the first and second panel~, when the m~i1.er is opened ~.
along the line of weaknes.s ~n A~hesive ~trip holding the .
panels together at that pojnt ~eing remo~7~d so that an open top of the reply envelope i.s provid~. The second sheet has only about two-thirds the dimensi.ons of the first sheet, and a bottom stnb is typic~lly provided at ::
the bottom of the return envelope between i.t and the fold line. U-shaped glue/adhesive p~tterns ~le provided for forming the reply envelope, ~n~ also for .~ealing the edges of the first and second pane].s together t:~ form a mailer constructed from the intermediAte.
The invention also compris~s a mail~r constructed - -from the intermediate describe~ above. Tlle mailer i5 ' constructed merely by V-fo].din~ ~bout th~ fold line and sealing adhesive patterns, the respositi.~n~l label with the outgoing address being vi.~ihle throl1~h the window cutout in the second panel. When the m~i.ler is received by the outgoing addressee, he or she opens it, detaches the reply envelope from the fi~t pane], repositions the repositional adhesive la~e1 so tl~at it i~ in the retllrn address portion of the rep]y en~lope r~tll~r th~n in the addressee portion (there~y cnvPli.ng the r1i.nted reply address), and mails it back to the origin~l. sender. The original sender may then ~Ise the repositinnal label as a ~ :
shipping label for a prod~lct tn ~e sent t~ the original outgoing addressee. ..
According to yet another ~spect of the present invention, a method of const.lllcting a m~;ler type b~l'siness ..
form i~ provided. The metho~ comprises th~ following steps: (a) Forming a fold J.in~ i.n the ir~t sheet to define first and second p~ne.ls, ~nd form;ng a die cut .
window in the second panel. ~b) Applyin~ An adhesive pattern to the first panel of the first ~heet for forming .
a reply envelope. (c) Printing a reply ~A~ress on a ;~
second æheet. (d) Applying the second sheet to the first sheet in registry with the reply envelope adhesive to form . ~ ~

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a reply envelope in the first p~nel, having dimensions . .
substantially less than th~ fir~t panel. (e) Forming perforations in the first and second panels. (f) Applying .:
adhesive for connection of the first and ~second panels together adjacent the edges thereof. (g) Blowing on a repositional adhesive label to cover the printed reply address on the second sheet. And, (h) V-folding the first sheet about the fold line so th~t the c~ out window is over the repositional adhe~ive .1.abel, an~ so that the adhesive connecting the panel~ together i~ flctivated to form a final mailer.
It is primary object of the present i.nvention to :~ :
provide a simple and advant.~geo~ls mailer, j.ntermediate for construction of the mailer, anc1 method of ~onstructing the :
mailer. While this and other objections of the invention will become clear from a deta.i].ed description of the invention and from the appende~ claims. ::
:' ; BRIEF DESCRIPTION OF T~E DRAWINGS
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FIGURE l is a top plan view of the "inside" face of a ;~
mailer type business form ]1lt.e~m~ te ~r:r~rding to the : invention;
., ,, . .,-FIGURE 2 is a view like th~t. of F~TlR~ l of the .
"outside" face of the mai]el i.tlt.ermedi~t.~;

FIGURE 3 is a top pl~n vi.~w of a cnl1strllcted mailer .. ;.
according to the invention;

FIGURE 4 is a top persrect;.ve view, with portions of :.~`~
the "second" sheet of the reply e11velope Cl1t away for : clarity of illustration, of an exemplary reply envelope of the mailer of FIGURES 1-3;

~FIGURE 5 is a rear view o the return envelope of : FIGURE 4; :
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'.' ~'.". ` ',''' ~' FIGURE 6 is a front view of the retl1rn envelope of FIGURE 4 showing the repositi.on~l label h~ving been removed to the return address position, and the reply ~. .
address clearly visible; and FIGURE 7 is a schemati.c representatioll of exemplary method steps that may be ~Itili7~d in the practice and the method according to the invent.ion, for plodtlcing the mailer of ~IGURES 1~3.

DETAIT.ED DESCRIPTION OF_~HE DRAWINGS

An exemplary intermedjate mailer tyr~ business form according to the present invent.ion is se~tl in ~IGURES 1 and 2, made from a first sheet of paper 1 n having a first face 11 which will become the i.nside face of the mailer, and a second face 12 (FIG. ~). The single sheet of paper .
10 is g~tadrate in configurAtion having first and second ..
parallel edges 13, 14 and thir~ and fo~lrth parallel edges 15, 16, the edges 15, 16 being perpendicll1.Rr to the edges 11, 12. A fold line 17 ~e.g., ~ score, r~r~oration nr the like) essentially bisects 1-]1~ ~d~es 15, 1~ and is :~
parallel to the edges ].3, ~ 4 . The fold l;lle 17 forms the -~
sheet 10 into a first panel ~8 ~nd a se~ panel 19. : :
A CUtO~It window 20, whicll preferably is covered by a --transparent "window" patc]~ formed in second panel :~
19. On the first face 11 a great deal of information is .:
printed, typically conf.ideJ~t.; Al informati nn. For example, an order form 22 (see FIG. J.) coltld be ~linted in one - :~
part, and other instructiona]. or like informatiortal indicia 23 printed on other pA~t9 . The ;n~.ide of the mailer to be constructed from tlle interm~diate 10 has a great deal of area that can be printed.
Also ~orming part of the i.ntermediate 10 of a mailer type business form according to the invent.ion is a reply ::
envelope formed from a quadrate second ~aper sheet 2S (see FIG. 1) which has dimensions sl~bstantialJ.y less than the dimension~ of the first panel ~.8, so as to allow for ~' ~ L iL 5 ~ 1 il printing of a great deal of ad~it.ional indicia, such as the order form indicia 22, on the first p~nel 18. A first adhesive pattern -- seen by the U-shaped ~attern 27 in FIGURE 4 -- connects the second sheet 25 to a part of the first panel 18, the adhesi~e of the pattern 27 being pasted pocket adhesive or the ]ike.
Printed on the second face 12 of the first sheet lO
(see FIG. 2) is the outgoing return address 29, and postage indicia 30. Printed on the second sheet 25 is reply address address indicia 31 (see FI~. 6), printed the ;~
same distance from the fold line 17 as t}-e cutout 20 and in alignment therewith so th~t when the ;ntermediate is folded about the fold line ~7 the area of the reply address 31 is visible thro11gh the cutout 20. However, the .
r~ply address 31 itself is not visible when the mailer is initially formed because a repositional ~dhesive label 32 ~ :
~see FIGS. l, 3 and 4) hav;1lg o11tgoing address information 33 printed thereon, cover~ the reply add~ess area 31 ~o that it is visible through the window 20. The repositional adhesive for t}~ el 32 m~y be of any ~ - .
conventional type, such ~s so~1 hy Moore B~1siness Forms, . ~.
of Lake Forest, Illinois, ~ Ae~ t.he tra~m~rk CLEANTAC. -:~
Note that the second sheet. ~ o may h~e reply address indicia printed thereon ;.n tlle ~rm of ~ har code as ~ :
indicated at 34 in FIGURE ].
As seen in FIGURE l, the ~cond she~t 25 has . .
dimensions of about two-third~ those of ~h~ first panel 18. Typically, a line of ~e~k1le.~s SllCh ;lS a perforation ~ ::
36 is provided at the bottom of the sheet ~5 between it ~ 4 and the old line 17. The dj.m~t~sion of ~he stub 37 formed between the lines 36, 17 determines the height of the reply envelope 38 (see FIG.~ fi) formed from the second sheet 25 and the underlying portion of the first panel 18 to which it i8 adhesively secured by the ~dhesive pattern 27. ~ ~ -The sheet lO also comprises a second adhesive ..
pattern, such as shown by the tl-shap~d pattern 40 in FIG. l, which may be heat sealable glue, for sealing the 7 ~ 5 ~ 1 ~

panels 18, 19 together adj~cent their ed~e~. While the pattern 40 may be applied on one or both of the panels 18, 19, the preferred construction illustrated in FIGURE 1 illustrates portions of the pattern 40 being provided adjacent both the third and follrth edge~ 15, 16 and the second edge 14 (remote from the fold line 17). In order to facilitate ready openillg of ~he mailer constructed from the intermediate of FIGURRS l`~nd 2, lin~R of weakness --such as the perforation line~ 4]., 42, 43 and 44 -- may be provided adjacent each of t~-e ~dges 13 thr~-lgh 16. Note that the perforation line 41 ha~ an exten.sion 45 into the second sheet 25.
The mailer 49 illustrated i.n FIGUR~ .~ is constructed from the intermediate of FJ~IJR~S 1 and ~ ~.mply by V-folding about the fold ljne 17 so th~t the portions of :~
face 11 are in engagement with e~ch other, with the adhesive pattern 4~ sealed. A~ can be ~en in FIGURE 3, the outgoing address 33 (an~ the repositional adhesive label 32) is visible through the cutout 20.
When the outgoing address~ gets th~ mailer 49, he or .
she detaches along the perforations 41, 4~, 43 and 44 to .
open up the mailer. Ex~e~t fo~ ~.hat pot~ n of the mailer ..
where the second and first ~lle~ts overl ~r ~djacent the first edge 13, there is only ~ rl~uble tl-;~knes~ of ~ :~
material so that the mailer 49 i.~ easy t~ ~pen up. The sheet 10 also preferably h~ the perfor~t~on lines 51, 52 (see FIG. 2) formed thereil~ to f~cilit~t~ ~etachment of the return envelope 38 on~e the mailer 4q has been opened up, including removal of the st7~hs 53 ~n~ .~7.
Once the return envelope ~ has bee~- ~etached from :~
the rest of the mailer 49, it ~n be stllffed as with the order form 22 portion of the f.;rst paneJ. 18, a check, or the like, the reply 0nvelope 3~ being sh~wn as a top opening envelope. Note that this top opening envelope 38 has a fold line 54 (~ee FIGS. 1 and 4) forming the flap 55 therefor, which has rewettable adhesive 56 (see FIG. 5~ or the like formed thereon so that the flap 55 can be folded over and then sealed in place to form a sealed reply :

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envelope 38 as illustrated in F~URE 6. A].so, in addition to stuffing the return envelope 38 and sea]ing it, the addressee takes off the repositi.onal label 32 and places it to the return address portion of the reply envelope 38 (see FIG. 6), the reply address 31 then being uncovered and visible on the front face (25~ of the return envelope 38. When the original addres.see receive~ the reply envelope 38, he or she can remove the repositional adhesive label 32 again and place that on ~ package to be sent to the original outgoing ~ddressee. ~ ~, FIGURE 7 schematical]y il]a~trates ~ method of ~:
producing a mailer 49 according to the invention. A first sheet lO of the mailer is forme~ from a web of paper that is preferably run on a 12" pres~. Here, ~s indicated by box 60, the perfs 51, 52, and the like, ~n be formed on the press, as by using a CH~MEX plate. The web then proceeds to stage 61 where it 1~ proces~d through a tight web machine where the heat sea] pattern (40) is applied.
Then, the sheet 10, in web form, passes to a stage 62 ~ ~-where the die cut window 20 is constructed, and then it passes to a stage 63 where past~rl pocket. ~hesive 27 for the reply envelope 38 is ~r1i~l. Me~nwl~; l e, the second sheet 25 is mounted on a p~t~h llllwind srin~le and every fiv~ and one-half inche~ or .CO ~ ~heet ~ ~ut from a web, as indicated in stage 64.
Stage 66 indicates where the .sheets 1~, 25 are registered to form the retl~n e~ elope 3R, using form-a-lîner punching, which is then sl.it- off. This combined web (67) is then fe~ to ~ perf.ing station 68 where marginal perfs 41 th~ough 45 are arplied, and then it passes to a stage 69 where ~ ~lue pat~h is supplied around the cutout 20 on face 11 and the t.rarlsparent window 21 i~ put in place. Ultim~tely (further perfing may be done), the web passes to stage 70 where t.he web is folded :
into pad form, and then is pa,ssed to st~ge 71 where the repositional adhesive label 32 i~ blown on utilizing a Labelaire~ machine. Finally, the pad form of mailers is .

fed to stage 72 where sheet ~0 is V-folded about fold line 17 and the adhesives heat sealed to form the mailer 49.
It will thus be seen that according to the present invention an advantageous m~.i le7-, intermPdlate, and method of CGnstruction thereof have been provided. While the invention has beerl herein shown and descrjbed in what is presently conceived to be the most practical and preferred :~
embodiment thereof, it will be apparent to those of ordinary skill in the art that matly modifi.cations may be made thereof within the scope of the im~ention, which scop~ is to be accorded the hroadest interpretation of the appended claims so as to encompa~s all egnivalent structures and procedures.

Claims (23)

1. An intermediate for a mailer type business form, comprising:
a first generally quadrate sheet of paper having parallel first and second edges, and parallel third and fourth edges perpendicular to the first and second edges;
a fold line substantially bisecting said third and fourth edges and parallel to said first and second edges, defining first and second panels;
means providing a cutout window in said second panel;
a reply envelope forming quadrate second sheet having dimensions substantially less than the dimensions of said first sheet;
a first adhesive pattern connecting said second sheet to said first sheet, first panel to form a reply envelope;
reply address indicia printed on said second sheet at a portion thereof in alignment with said cutout window when said first sheet is V-folded about said fold line;
a repositional adhesive label applied to said second sheet covering said reply address, and having an outgoing address thereon;
a second adhesive pattern for connecting said first panel to said second panel along the edges thereof when V-folded about said fold line; and lines of weakness formed in said first and second panels adjacent said edges of said first sheet for allowing ready opening of a mailer formed by V-folding about said fold line and adhesive attachment by said second adhesive.

2. An intermediate as recited in claim 1 wherein said reply address indicia is readable in a line, said readable line being parallel to said fold line.

3. An intermediate as recited in claim 2 further comprising a third adhesive pattern connecting said second sheet to said first sheet along said first edge of said first sheet, and detachable from said reply envelope when said first and second panels are detached at said lines of weakness.

4. An intermediate as recited in claim 3 wherein said return envelope includes a flap, and further comprising a fourth pattern of adhesive formed on said flap.

5. An intermediate as recited in claim 2 wherein said first adhesive pattern has a U-configuration.

6. An intermediate as recited in claim 5 wherein said U-configuration of said first adhesive pattern is oriented, with respect to said reply address indicia, so as to provide an open top of said reply envelope.

7. An intermediate as recited in claim 2 wherein said second adhesive pattern comprises a U-configuration being provided adjacent said third and fourth edges in at least one of said panels, and adjacent either said second or first edge.

8. An intermediate as recited in claim 7 wherein said second adhesive pattern comprises heat seal adhesive disposed adjacent said second edge, and adjacent said third and fourth edges on said second panel.

9. An intermediate as recited in claim 1 wherein said second sheet has approximately two-thirds the area of said first panel.

10. An intermediate as recited in claim 9 further comprising perforations disposed adjacent said fold line in said first panel, between said second sheet/reply envelope and said fold line.

11. A mailer type business form comprising:
a first generally quadrate sheet of paper having parallel and aligned first and second edges, and parallel third and fourth edges perpendicular to said first and second edges; said first sheet V-folded about a fold line to form first and second panels;
means providing a cut out window in said second panel;
a reply envelope formed by a quadrate second sheet having dimensions substantially less than the dimensions of said first sheet, and adhesively secured by a first adhesive pattern to said first sheet first panel to form a reply envelope;
reply address indicia printed on said second sheet at a portion thereof in alignment with said cut out window of said second panel;
a repositional adhesive label applied to said second sheet covering said reply address, and having an outgoing address thereon;
a second adhesive pattern for connecting said first panel to said second panel along the edges thereof; and lines of weakness formed on said first and second panels adjacent said edges of said first sheet inside of said second adhesive pattern, for allowing ready opening of said mailer.

12. A mailer as recited in claim 11 wherein said reply address indicia is readable in a line, said readable line being parallel to said fold line.

13. A mailer as recited in claim 12 further comprising a third adhesive pattern connecting said second sheet to said first sheet along said first edge of said first sheet, and detachable from said reply envelope when said first and second panels are detached at said lines of weakness.

14. A mailer as recited in claim 13 wherein said return envelope includes a flap, and further comprising a fourth pattern of adhesive formed on said flap.

15. A mailer as recited in claim 11 wherein said first adhesive pattern has a U-configuration.

16. A mailer as recited in claim 15 wherein said U-configuration of said first adhesive pattern is oriented, with respect to said reply address indicia, so as to provide an open top of said reply envelope.

17. A mailer as recited in claim 11 wherein said second adhesive pattern comprises a U-configuration being provided adjacent said third and fourth edges in at least one of said panels, and adjacent either said second or first edge.

18. A mailer as recited in claim 17 wherein said second adhesive pattern comprises heat seal adhesive disposed adjacent said second edge, and adjacent said third and fourth edges on said second panel.

19. A mailer as recited in claim 11 wherein said second sheet has approximately two-thirds the area of said first panel.

20. A mailer as recited in claim 19 further comprising perforations disposed adjacent said fold line in said first panel, between said second sheet/reply envelope and said fold line.

21. A method of forming a mailer type business form with a built in reply envelope, utilizing a first sheet of paper having first quadrate dimensions of first and second panels thereof, and a second sheet of paper having second quadrate dimensions much less than the first dimensions, comprising the steps of:

(a) forming a fold line in the first sheet to define first and second panels, and forming a die cut window in the second panel;
(b) applying an adhesive pattern to the first panel of the first sheet for forming a reply envelope;
(c) printing a reply address on a second sheet;
(d) applying the second sheet to the first sheet in registry with the reply envelope adhesive to form a reply envelope in the first panel, having dimensions substantially less than the first panel;
(e) forming perforations in the first and second panels;
(f) applying adhesive for connection of the first and second panels together adjacent the edges thereof;
(g) blowing on a repositional adhesive label to cover the printed reply address on the second sheet; and (h) V-folding the first sheet about the fold line so that the cut out window is over the repositional adhesive label, and so that the adhesive connecting the panels together is activated to form a final mailer.

22. A method as recited in claim 21 comprising the further step of opening the mailer by tearing along the perforations; removing the reply envelope from the first panel; removing the repositional label from its position covering the reply address, and placing it on a return address portion of the reply envelope; stuffing the reply envelope; sealing the reply envelope; and returning the reply envelope to the reply addressee.

23. A method as recited in claim 22 comprising the further step of, upon receipt of the reply envelope removing the repositional label therefrom, and applying the repositional label to a package and sending the package to the original outgoing addressee of the mailer.