EP0055509B1

EP0055509B1 - A continuous form assembly of mailer sets

Info

Publication number: EP0055509B1
Application number: EP19810304895
Authority: EP
Inventors: James M. Turner; Leo H. Miller
Original assignee: Burroughs Corp
Current assignee: Unisys Corp
Priority date: 1980-12-16
Filing date: 1981-10-20
Publication date: 1984-09-12
Also published as: JPS57125099A; CA1190262A; AU7634781A; EP0055509A1; AU547810B2

Description

Background of the Invention

A. Field of the Invention

This invention relates to continuous business forms and more particularly to multiple-ply continuous mailer set assemblies.

B. Prior Art

Many prior art assemblies in this field experienced problems of "tenting". This phenomena is so named because when the zig-zag stack, into which the forms are initially folded, is unfolded, a tent-like peak appears at each fold line. This tent-like peak is caused by the longitudinal movement of the various plies, one to another, as the forms are originally folded. The relative movement, in turn, is caused by slippage between the forms at the fold before the glue dries.
A further problem was caused by the use of excessive glue. This came about as the result of the use of a glue line between each of the multiple plies. This excessive use of glue caused stiffness in the stub portion of the assembly and thereby made the forms difficult to feed through automatic printing equipment.
US-A-3,104,799 and 3,339,827, and US-A-3,554,438 illustrate examples of the continuous business form art. In all of these patents, the interior piles are contained by gluing between each of the plies. The gluing may be done in either the left or right hand stubs. The plies are held in proper registration by leaving a stub continuous in either the left or the right hand stub. As mentioned earlier, it is this multiplicity of glue layers as well as this continuous stub which causes both the stiffness in the stub and the tenting problems.
FR-A-2 267 949, discloses the provision of separate packages of interior plies joined by a common longitudinal detachable band on one or both edges of continuous succession of mailer set assemblies. The packages of interior plies are longitudinally equispaced, allowing the outer plies to be transversely glued together therebetween and allowing the succession of mailer set assemblies to be fanfolded without tenting.
US-A-3 325 188, discloses a continuous succession of transversely separable mailer set assemblies wherein a pair of outer plies and one or more interior plies are joined together by a common glue line deposited on only one of the outer plies by virtue of the one or more interior plies comprising a row of perforations, co-incident with the one glue line, wherethrough glue from the line may seep between the outer plies to join them and the one or more inner plies together.
FR-A-2 267 949 goes some way towards improving the transverse flexibility of continuous mailer set assemblies, but there still remain problems associated with rigidity caused by the common bonding of many plies by many glue lines. US-A-3 325 188 in part solves the rigidity problem of the many glue lines by using just one glue line, but fails to control the transverse seepage between plies of glue when many plies are to be joined in common, thereby leaving a residual flexibility problem.
Accordingly, it is an object of this invention to provide a unique and simple continuous form mailer set assembly which solves not only the stub stiffness problem but the tenting problem as well. This solution is achieved while still maintaining the registration of the internal plies.
It is another object of this invention to provide a continuous mailer set form whose multiple interior plies are contained on both longitudinal sides of the assembly.
It is still another object of this invention to provide a continuous mailer set form whose interior plies are contained by the use of a single bead of glue on either side of the assembly.
It is another object of this invention to provide a continuous mailer set form whose interior plies each have a series of corresponding holes along either of their longitudinal sides.
It is still a further object of this invention to provide a continuous business mailer set form whose multiple interior plies are glued together via a single glue bead longitudinally passing adjacent to and bleeding through a series of punched holes in all of said interior plies.
The present invention consists in a continuous form mailer set assembly comprising a continuous face ply, a continuous back ply, and a plurality of packets of one or more interior plies, where said packets of interior plies are individually separate and positioned longitudinally between said face ply and said back ply, where each of said packets of interior plies is attached between said face ply and said back ply along both of its longitudinal edges to permit said face ply and said back ply to be transversely folded between successive ones of said plurality of packets of interior plies with only said face ply and said back ply included in the fold, and where said back ply comprises a pair of single glue lines, one along each of the longitudinal edges of the assembly said assembly being characterised by each of said packets of one or more interior plies comprising a corresponding pair of series of punched slots along its longitudinal edges, directly adjacent to said glue lines for the glue from each of said longitudinal glue lines to bleed through said punched slots to join said back ply, said one or more interior plies and said face ply together, said face ply further comprising a pair of single longitudinal glue lines, one along each of the longitudinal edges of said assembly adjacent to said punched slots for the glue from said longitudinal glue lines on the said face ply to bleed through said slots to meet with the glue bleeding through said slots from the longitudinal glue iines on said back ply whereby the amount of glue in each of said glue lines can be reduced to prevent lateral seepage of said glue between the plies.
In the preferred embodiment of this invention, a continuous mailer set form assembly is provided which comprises a plurality of interior plies within each mailer set. The multiplicity of interior plies in each mailer set are attached between a front and a back longitudinally continuous sheet at both their left and their right hand edges. A series of holes are punched entirely through the plurality of interior plies along their right and left edges parallel to the longitudinal path of the continuous form. A left and right hand glue line runs adjacent to the series of punched holes such that the glue bleeds through the holes of the interior plies to permanently attach the interior plies. As the continuous form is folded in a zig-zag manner, the only material included at the successive folds are the front and back sheet. Further, the interior plies are all glued via a longitudinal pair of single glue lines rather than the successive layers of interior plies and glue lines. The resulting configuration provides a unique continuous mailer set assembly having improved tenting characteristics and increased flexibility through a reduction in glue lines. This improvement is accomplished while maintaining interior ply registration.
The foregoing objects and the summary will be more readily understood when read in conjunction with the accompanying drawings in which

Figure 1 illustrates a prior art continuous form showing the continuous stub characteristics, the single side registration and the multiple glue lines,
Figure 2 illustrates the present invention showing the double side registration, the lack of a continuous stub and the reduction in glue lines.

Detailed Description of the Invention

The following detailed description will be more easily comprehended when it is read with reference to the drawings in which like reference characters symbolize corresponding parts.
Figure 1 illustrates the prior art continuous form 10 which includes the top sheet 12 and the bottom sheet 14. Sandwiched between these two sheets 12 and 14 is a plurality of interior plies 16. Between each of the interior plies is a glue line 18. As is shown, there is a plurality of glue lines 18 equal to one less than the plurality of interior plies 16. Further, there are continuous stubs 20 connecting successive groups of these interior plies 16.
It is believed readily apparent that significant problems will exist when this continuous form 10 is zig-zag folded at the fold lines. Thus, as the number of interior plies 16 is increased, the thickness of the continuous stub 20 increases. This increase in thickness prevents a smooth folding of the form 10 at the fold lines. Since the glue used is usually not dry at the time of folding, there is a relative shift of the interior plies one to another and this results in the tenting problem previously discussed. This problem is well known in the art to which this invention relates.
Further, as the number of interior plies increases the number of glue lines 18 which exist between the individual interior plies also increases. This increase in the plurality of glue lines stiffens the edge of the form and this results in decreased flexibility. Consequently, the form does not adapt to automatic printing equipment as easily as it might.
In summary, in prior art the interior plies are contained by gluing between each ply in either the left or right stub. The plies are held in register by leaving a stub continuous on either the left or right side. This type of construction has several problems. The glue line is put down between each ply in the continuous stub, which is a major contributor to tenting (slippage between the forms at the fold before the glue dries). Gluing between each ply also leaves an excessive amount of glue in that stub causing stiffness in the stub which makes the forms difficult to feed through automatic printing equipment.
The construction shown in Figure 2 eliminates problems while still maintaining the registration of the internal plies. Figure 2 shows an exploded view of a typical mailer set 40 showing the interior plies 36 extending into both line hold stubs 54. It should be noted that there is no continuous stub on either side of the. interior plies; they are completely separated from each other. This means that there are only two plies glued together where the form is folded at the folding lines, which eliminates the tenting problem.
Slots 34 are punched through all the interior plies 36 on both ends thereof, a short distance toward the center of the form from each line hole stub perforations 48. The glue lines 38 are applied to both the back of the face ply 42 and on the face of the back ply 44. The glue lines 38 are put down so that when the form 40 is assembled, these glue lines fall underneath and above the punched slots 34 in the interior plies 36. This allows the glue to bleed through the slots 34, sealing both of the ends of the outer plies 42, 44 of the mailer 40 together. Because there are only two glue lines on each mailer, no matter how many interior plies there are, the resulting stubs 56, 58 are much more flexible and easier to feed through automatic printing equipment.
The mailer set is opened by removing the tear off stub 56 at the tear off perforation 50. This perforation 50 is on all plies, face, back and all interior plies. The interior plies are then grasped at the thumb point 60 and snapped out breaking loose at the snap perforation 52.
It will be understood from the foregoing description that various modifications and changes may be made in the preferred embodiment of the present invention. It is intended that this description is for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be limited only by the language of the following claims.

Claims

1. A continuous form mailer set assembly (40) comprising a continuous face ply (42), a continuous back ply (44), and a plurality of packets of one or more interior plies (36), where said packets of interior plies (36) are individually separate and positioned longitudinally between said face ply (42) and said back ply (44), where each of said packets of interior plies (36) is attached between said face ply (42) and said back ply (44) along both of its longitudinal edges to permit said face ply (42) and said back ply (44) to be transversely folded between successive ones of said plurality of packets of interior plies (36) with only said face ply (42) and said back ply (44) included in the fold, and where said back ply (44) comprises a pair of single glue lines (38), one along each of the longitudinal edges of the assembly (40) said assembly being characterised by each of said packets of one or more interior plies (36) comprising a corresponding pair of series of punched slots (34) along its longitudinal edges, directly adjacent to said glue lines (38) for the glue from each of said longitudinal glue lines (38) to bleed through said punched slots to join said back ply (44), said one or more interior plies (36) and said face ply (42) together, said face ply (42) further comprising a pair of single longitudinal glue lines (38), one along each of the longitudinal edges of said assembly (40) adjacent to said punched slots (34) for the glue from said longitudinal glue lines (38) on the said face ply (42) to bleed through said slots (34) to meet with the glue bleeding through said slots (34) from the longitudinal glue lines on said back ply (44) whereby the amount of glue in each of said glue lines (38) can be reduced to prevent lateral seepage of said glue between the plies (36, 42, 44).

2. A continuous form mailer set assembly (40) according to claim 1 further characterised by comprising a plurality of glue spots (32) positioned transversely on one or the other of said continuous face ply (42) or said continuous back ply (44) between said packets of one or more interior plies (36) spaced equally on each side of the fold line such that said continuous face ply (42) is directly joined to said continuous back ply (44) on both sides of the fold line.

3. A continuous form mailer set assembly (40) according to claim 1 or claim 2 characterised by comprising a plurality of line holes (46) positioned along each longitudinal edge of said assembly (40) for use in the automatic processing of the assembly (40).

4. A continuous form mailer set assembly (40) according to claim 3 further characterised by comprising a pair of perforation lines (48) just inboard of said plurality of line holes (46).

5. A continuous form mailer set assembly (40) according to claim 4 further characterised by comprising a single tear-off perforation line (50) positioned further inboard than one of the pair of perforation lines (48) and perforating entirely through said assembly (40) along that line (50).

6. A continuous form mailer set assembly (40) according to claim 5 further characterised by said one or more interior plies (36) comprising a snap perforation line (52) on the opposite side of said assembly (40) to said tear-off perforation line (50), said snap perforation line (52) only perforating said one or more interior plies (36) in said each one of said packets.