WO1997044198A1

WO1997044198A1 - Multi-layer post card and method for manufacturing same

Info

Publication number: WO1997044198A1
Application number: PCT/US1996/012157
Authority: WO
Inventors: Howard G. Rockett; David K. Downey
Original assignee: Rockett Howard G; Downey David K
Priority date: 1996-05-22
Filing date: 1996-07-24
Publication date: 1997-11-27
Also published as: AU6595896A

Abstract

A multilayer postcard (10) with a releasable inscription surface comprises a paperboard layer (12) having opposed first and second surfaces, each of which includes printed material (15, 17) thereon, a paper layer (22) having opposed first and second surfaces, and an adhesive layer formed of a releasable adhesive being positioned between the paper layer and the paperboard layer (12) to bond the paperboard layer and the paper layer in overlying relationship. The second paper surface faces the first paperboard surface, and the first paper layer surface is exposed to receive an inscription. The releasable adhesive is selected to have a greater adhesion to the paper layer than to the paperboard layer (12) such that, upon peeling of the paper layer (22) from the paperboard layer the paperboard layer (22) is essentially free of the adhesive and essentially all of the adhesive remains adhered to the paper layer second surface.

Description

MULTI-LAYER POST CARD AND METHOD FOR MANUFACTURING SAME

Field of the Invention

The present invention relates generally to postcards, and relates more specifically to collectible postcards.

Background of the Invention

Postcards are commonly used as an alternative to letters or packages. Typically, the postage for a postcard is considerably less than that of an enveloped letter; thus, if the message to be conveyed is one that need not be concealed by an envelope, a postcard can be a viable, lower cost alternative. The difference in cost can be considerable, particularly if the sender is in a foreign country. Also, if a message is to be sent to a large number of recipients (such as in a direct mail advertising program or a political campaign) , the use of postcards as the postal vehicle can provide significant savings in postage costs.

Picture postcards are often sold at vacation resorts, historical and geological landmarks, and the like as a means for sending a message and illustrating some aspect of the location to the recipient. A picture postcard is typically formed of a relatively stiff sheet material (generally relatively thin cardboard or paperboard) . One surface of the typical picture postcard has a picture or design that is often somehow related to the location where the postcard was purchased, while the opposite surface includes space suitable for inscribing a message and the addressee's name and address and for affixing postage. In many instances, the picture postcard is a collectable item that the recipient wishes to save as a memento.

A particular shortcoming of this variety of the typical picture postcard is that it includes only one complete surface for designs or pictures, as the other surface reserves at least some space for addressee information and postage. If the postcard designer wishes to include multiple pictures or designs on a single postcard, he must shrink all of the pictures to fit within the space provided on the picture surface, or he must somehow include shrunken versions of one or more of the pictures on the writing surface without unduly limiting the available addressee, message and postage space. Shrinking the pictures may not be acceptable, as the shape or subject of the pictures or their juxtaposition may adversely affect the appearance of the postcard. Also, including a picture on the writing surface will almost certainly significantly reduce the available writing space. One shortcoming of the typical direct-mail postcard is its mundane appearance. Many recipients of direct-mail postcards are inundated with such postcards advertising all sorts of products and services. As a result, the recipients often simply dispose of direct- mail postcards without paying them much, if any, attention. Consequently, direct-mail advertisers are constantly searching for new features to attract and retain a recipient's interest.

Summary of the Invention In view of the foregoing, it is an object of the present invention to provide a picture postcard which includes increased surface area for pictures or illustrations . It is also an object of the present invention to provide a picture postcard which includes such increased surface area without limiting available writing space. It is an additional object of the present invention to provide a direct-mail advertising postcard having increased recipient appeal .

It is a further object of the present invention to provide a manufacturing method and an associated apparatus for producing such postcards.

These and other objects are satisfied by the present invention, which as a first aspect provides a multilayer postcard having a releasable inscription surface. The multilayer postcard comprises a paperboard layer having opposed first and second surfaces, each of which includes printed material thereon, a paper layer having opposed first and second surfaces, and an adhesive layer formed of a releasable adhesive being positioned between the paper layer and the paperboard layer to bond the paperboard layer and the paper layer in overlying relationship. The second paper surface faces the first paperboard surface, and the first paper layer surface is exposed to receive an inscription. The releasable adhesive is selected to have a greater adhesion to the paper layer than to the paperboard layer such that, upon peeling of the paper layer from the paperboard layer the paperboard surface is essentially free of the adhesive and essentially all of the adhesive remains adhered to the paper layer second surface.

As such, the postcard of the present invention provides a collectible item having two complete surfaces for pictures, illustrations, and other visual images while still providing a complete inscription surface. It is contemplated that the visual surfaces of the paperboard layer be thematically related, such as each being directed to a historical or geographic landmark.

In a preferred embodiment, the paperboard layer of the postcard includes a gloss-imparting coating on one or both of its first and second surfaces. It is also preferred that the adhesive comprising the adhesive layer be a natural or synthetic latex-based aqueous solution.

As a second aspect, the present invention provides a method for forming a multilayer postcard. The method comprises the steps of: forming a paperboard layer having opposed first and second surfaces, each of which has printed material thereon; forming a paper layer having first and second surfaces, with the first surface being conformed for receiving an inscription thereon; applying a releasable adhesive layer to the paper layer second surface; and adhering the paperboard layer to the paper layer such that the second paper layer overlies and faces the first paperboard layer. The releasable adhesive, paper, and paperboard are selected so that, upon peeling of the paper layer from the paperboard layer, essentially all of the adhesive comprising the adhesive layer adheres to the paper layer, and the first paperboard surface is essentially free of adhesive. It is preferred that the method include the step of applying a gloss-imparting coating to the first and second surfaces of the paperboard layer prior to adhering the paperboard layer to the paper layer.

Brief Description of the Figures

Figure 1 is a perspective view of a multilayer postcard of the present invention.

Figure 2 is a perspective view of the multilayer postcard of Figure 1 with its paper sheet partially peeled from its paperboard sheet. Figure 3A is a perspective top view of the exposed paperboard layer of the postcard of Figure 1.

Figure 3B is a perspective bottom view of the paperboard layer of the postcard of Figure 1. Figure 4 is a greatly enlarged partial end view of the multilayer postcard of Figure 1.

Figure 5 is a schematic illustration of a process for printing paperboard sheets.

Figure 6 is a schematic illustration of a process for printing paper sheets and applying adhesive to one surface thereof .

Figure 7 is a schematic illustration of a process for combining printed paperboard sheets with printed, adhesive-carrying paper sheets and cutting them to produce postcards of the present invention.

Detailed Description of the Preferred Embodiment

The present invention will now be described more particularly hereinafter with reference to the accompanying drawings, in which a present embodiment of the invention is shown. The invention, however, may be embodied in many different forms and is not limited to the embodiment set forth herein; rather, this embodiment is provided so that the disclosure will fully convey the scope of the invention to those skilled in the art.

Referring now to the Figures, a multi-layer postcard, designated broadly at 10, is illustrated in Figures 1 through 4. The multi-layer postcard 10 comprises a paperboard layer 12 and a overlying paper layer 22 bonded thereto via a releasable adhesive layer 30. The paperboard layer 12 includes upper and lower surfaces 14, 16, each of which displays a respective printed image 15, 17. The upper and lower surfaces 14, 16 also include respective overlying coating layers 18, 19 (see Figure 4) . The paperboard layer 12 can be formed of any paperboard known to those skilled in the art to be suitable for a postcard. Because it is anticipated that the paperboard layer 12 may be a collectible item, it may be desirable that the paperboard layer 12 be of a thickness to impart durability thereto. Preferably, the paperboard layer 12 has a thickness of between 0.010 and 0.050 inches, and is more preferably formed of about 24 point paper stock (i.e. , 0.024 inches) . It is also preferred that the paperboard comprising the paperboard layer 12 include an enamel or clay coating to improve printing quality.

The printed images 15, 17 of the upper and lower surfaces 14, 16 (see Figures 3A and 3B) can be any printed images suitable for inclusion on a paperboard layer 12. The images 15, 17 can be monochromatic or polychromatic, with polychromatic images being preferred, and can be imprinted through any method known by those skilled in this art to be suitable for the transfer of printed images to a paperboard sheet .

Preferably, the printed image 15 is thematically related to the printed image 17. For example, the printed images 15, 17 may be directed to a recipe for a comestible preparation, with a photograph or other illustration of the comestible preparation being printed on the upper surface 14 and the recipe for preparing the comestible preparation on the lower surface 16. As another example, the printed images 15, 17 can be directed to a geographic or historical landmark, with one of the images being a current photograph or other representation of the landmark and the other image being a historical photograph or representation, facts about the landmark, or a combination thereof. As a further example, the printed images 15, 17 can be similar to those found on a typical trading card, such as those produced for sports figures. In that event, one of the images may be a photograph of the sports figure, with the other image containing facts about that sports figure's career. It is also contemplated that the multi- layered postcard 10 can be utilized in direct mail advertising. In one embodiment, the printed image 15 would include illustrations and or information regarding a particular product or service, and the printed image 17 would include text, symbols, and the like which enable the recipient of the postcard 10 to respond to the advertisement through the mail. For example, the printed image 17 may include boxes or lines to be "checked" by the recipient to indicate interest in particular products or services. The printed images 15, 17 are protected and enhanced by respective overlying coating layers 18, 19 (Figure 4) . The coating layers 18, 19, which are typically formed of the same coating material, are included to protect the printed images and to impart gloss to the lower and upper surface 14, 16. The coating material should be selected so that the releasable adhesive layer 30 can adhere thereto but releases therefrom preferentially so that essentially all of the adhesive layer remains adhered to the paper layer 22.

The coating is preferably an epoxy-acrylate- based coating, which may include additives such as silicon and waxes for improved wetting and abrasion resistance. Epoxy acrylate coatings are typically curable with ultraviolet light, which can simplify manufacturing. Exemplary epoxy acylate coatings include MIRACURE^® coatings, such as J93220, available from Pierce & Stevens, Buffalo, New York. If an epoxy acylate coating is employed, a primer, such as a water- based styrene-acrylic solution, may precede application of the coating, or a clay-coated paperboard layer 12 may be used, to prevent the coating from soaking too deeply into the paperboard layer 12 for proper curing.

The paper layer 22, which overlies the paperboard sheet 12 , includes lower and upper surfaces 23, 24 (Figures 1, 2 and 4), with the lower surface 23 facing the upper surface 16 of the paperboard layer 12. The paper layer 22 is preferably sized and configured such that its perimeter is substantially aligned with the perimeter of the paperboard layer 22. The upper surface 24 includes a printed image 26, which most typically will include lines indicating where addressee information should be inscribed and postage affixed. Illustratively and preferably, one corner 27 of the paper layer 22 includes an arcuate cut 28 to provide a starting point for peeling. Preferably, the paper layer 22 is a matte sheet (i.e. , is formed via a matte process and has a relatively dull finish) , which is particularly suitable for receiving a manual or automatically produced inscription. Preferably, such a matte sheet has a thickness of between about 0.003 and 0.010 inches, and is formed of 100 pound text paper for durability (i.e. , 0.0055 inches) .

The releasable adhesive layer 30 (Figures 2 and 4) overlies the paper layer upper surface 24. The adhesive forming the adhesive layer 30 should be selected such that it has greater adhesion to the paper layer upper surface 24 than to the coating layer 19 of the paperboard layer lower surface 16. As such, when the paper layer 22 is peeled from the paperboard sheet 12, the paperboard layer 12 is essentially free of the adhesive comprising the adhesive layer 30, and essentially all of the adhesive layer 30 remains adhered to the paper layer 22. Particularly suitable adhesives for forming the adhesive layer 30 include water based-adhesives which include a synthetic resin or natural latex base, with natural latex adhesives being particularly preferred. An exemplary water-based natural latex adhesive suitable for the adhesive layer 30 is Product No. C-0551, available from H.B. Fuller Company, Cincinnati, Ohio. The adhesive may include defoamers, plasticizers, surfactants, humectifiers, tackifiers, and other additives and still be suitable for use with the present invention.

A sheet-fed offset process for producing the multi-layer postcard 10 is illustrated in Figures 5 through 7. A printing machine 40 for producing paperboard sheet is shown in Figure 5. The printing machine 40 includes six color stations 42a, 42b, 42c, 42d, 42e, 42f, in which color is imparted to paperboard sheet 41. Each paperboard sheet 41 is preferably sized (for example, 28 inches x 40 inches) so that a plurality of paperboard layers for postcards can be produced thereon. Each color station 42a, 42b, 42c, 42d, 42e, 42f includes an ink train 44 or other ink source, a plate cylinder 46 for transferring ink from the ink train 44, a blanket cylinder 48 which receives ink from the plate cylinder 46, and an impression roller 50 positioned beneath the blanket cylinder 48 (illustrated schematically within and adjacent color station 42c) . During printing, a paperboard sheet 41 is conveyed from a stack thereof through the color stations by transfer rolls 52, 53, which convey the paperboard sheets 41 between a nip formed by the blanket cylinder 48 and the impression roller 50. As the paperboard sheet 41 travels through this nip, ink is transferred from the blanket cylinder 48 to the paperboard sheet 41.

Typically, each color station 42a, 42b, 42c, 42d, 42e, 42f will impart a different color to the paperboard sheet. For example, the color station 42a may transfer black, and the color station 42b may transfer blue, with color stations 42c and 42d transferring red and yellow respectively. Color stations 42e and 42f can be employed to transfer a spot color, such as that used to tint or enhance the background of the paperboard sheet 41.

After one surface of the paperboard sheet 41 has been printed, it is then conveyed through an aqueous primer coating station 56, wherein an aqueous primer is applied. Next, the paperboard sheet 41 is conveyed to an ultraviolet coating station 58, wherein the ultraviolet coating layer is applied. Each of these components is preferably applied with a roller. The paperboard sheet 41 is then conveyed to a coating dryer 59 for drying; if, as illustrated, an ultraviolet light-cured coating is employed, typically the coating dryer 59 will include ultraviolet lamps to cure the coating. After travelling through the printing machine

40, one surface of the paperboard sheet 41 has been printed and coated. The paperboard sheet 41 is then inverted and conveyed through a similar printing machine (not explicitly illustrated) to have its opposed surface printed and coated. At that point, the printing and coating of the paperboard sheet 41 is complete, and the paperboard sheet 41 can be combined with a suitable paper sheet.

Although the sheet-fed printing process described hereinabove is preferred, it is contemplated that the paperboard sheets 41 can also be produced by other printing processes, as web-offset printing.

The paper layers can be produced on a sheet- fed printing machine such as that schematically illustrated at 60 in Figure 6. The printing machine 60 includes color stations 61a, 61b, 61c, 61d, 61e, 61f similar to those of the printing machine 40 of Figure 5, with a similar ink train 66, a plate cylinder 68, a blanket cylinder 70, an impression cylinder 72 and transfer rollers 74, 76.

After a matte sheet 62 has been printed by the printing machine on one surface, adhesive is applied to its opposite surface at an adhesive station 80. The adhesive station 80, (which illustratively and preferably is a pot devin configuration) includes a basin 82 containing a releasable adhesive 84. A pickup roller 86 is positioned so that its lower portion is immersed in the adhesive 84. A transfer roller 88 is positioned to receive adhesive from the pickup roller 86 and transfer it to the matte sheet 62. An anvil roller 90 is positioned above the transfer roller 88 to provide a nip through which the matte sheet 62 can be conveyed. As it travels through the nip, the matte sheet 62 receives an adhesive layer on one surface. After its transport through the adhesive station 80, the matte sheet 62 can be combined with a paperboard sheet 41.

Referring now to Figure 7, the matte sheet 62 and paperboard sheet 41 are aligned and lightly pressed together by hand, with the adhesive on the matte sheet 62 adhering to the upper surface of the paperboard sheet 41. These combined layers are then conveyed through the nip formed by a pair of pressure rollers 100, 102; the process presses the paperboard sheet 41 and the matte sheet 62 together to form a multilayer sheet 103 and removes therefrom imperfections, such as air bubbles. The multilayer sheet 103 is then conveyed to a perforating die 104, which makes small arcuate cuts in the matte sheet 62 which will ultimately form the perforated corners of a postcard described hereinabove. Still referring to Figure 7, the multilayer sheet 103 is then conveyed to a translating turntable 108 which is positioned beneath a guillotine knife 106. The guillotine knife 106 is lowered onto the multilayer sheet 103 as it is translated longitudinally to impart transverse cuts in desired locations, thereby forming the multilayer sheet 103 into a plurality of multilayer strips. Once these cuts have been made, the strips are rotated 90 degrees about a vertical axis with the turntable 108, and the guillotine knife 106 is again lowered to make transverse cuts in desired locations. This second set of transverse cuts forms the strips into a plurality of postcards 110.

Use of the multilayer postcard 10 is illustrated in Figures 1 through 3. A complete postcard 10 can be inscribed with addressee information either manually by the sender, as would likely be the case for a collectible picture postcard, or can be inscribed automatically by processing such information by any method known to those skilled in this art. The postcard 10 is then sent to the addressee. Upon its receipt, the addressee removes the paper layer 22 by peeling it from the paperboard layer 12 (Figure 2) .

Because the adhesive layer 30 preferentially adheres to the paper layer 22 rather than the paperboard layer 12, essentially all of the adhesive layer 30 is carried by and remains with the paper layer 22, and the paperboard layer 12 is essentially free of adhesive.

Consequently, the paperboard layer 12 can provide an aesthetically-pleasing collectible postcard, the appearance of which is unmarred by remnants of adhesive. It is also contemplated that the multi- layered postcard 10 may be configured to include a microencapsulated "fragrance burst," in which a fragrance is released as the paper layer 22 is peeled from the paperboard layer 12. A sample of the fragrance can be included within one or more microencapsulating membranes that are adhered to the paperboard and paper layers . When the paper layer is peeled, the membranes rupture, thereby releasing the fragrance sample. This postcard embodiment may be employed in a direct mail advertising campaign to place new fragrances before the consuming public. It is also contemplated that an additional paper layer can be releasably adhered to the lower surface 16 of the paperboard layer 12 to cover the printed image 15. In this embodiment, two full inscription surfaces would be provided, each of which covers a respective printed image.

The foregoing demonstrates how the postcard of the present invention addresses concerns presented by prior art postcards. First, it provides two full postcard surfaces for photographs, illustrations, and other visual representations (see Figures 3A and 3B) as well as at least one full inscription surface for addressee information and messages. The dual surfaces for printed images can render the postcard more appealing for sending and for collecting. Also, postcards of this variety can provide an effective direct-mail vehicle; they differ from conventional postcards and therefore may capture the addressee's attention more readily, and they provide an actual task to perform (i.e. , removing the paper layer) which may further attract and keep the addressee's attention.

The foregoing embodiments are illustrative of the present invention, and are not to be construed as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein.

Claims

THAT WHICH IS CLAIMED IS:

1. A multi-layer postcard having a releasable inscription surface, comprising: a paperboard layer having opposed first and second surfaces, each of said first and second surfaces including printed material thereon, a paper layer having opposed first and second surfaces, said paper layer being formed of a material suitable for receiving an inscription; and an adhesive layer formed of a releasable adhesive being positioned between said paper layer and said paperboard layer to bond said paperboard layer and said paper layer in overlying relationship, with said second paper surface facing said first paperboard surface and said first paper layer surface being exposed to receive an inscription, said releasable adhesive being selected to have a greater adhesion to said paper layer than to said paperboard layer such that, upon peeling of said paper layer from said paperboard layer, said paperboard layer is essentially free of said adhesive and essentially all of said adhesive remains adhered to said paper layer second surface.

2. The multi-layer postcard defined in Claim 1, wherein said first paperboard layer surface includes a gloss-imparting coating.

3. The multi-layer postcard defined in Claim 3, wherein said gloss-imparted coating is curable with ultraviolet light.

4. The multi-layer postcard defined in Claim 3, wherein said gloss-imparting coating is an epoxy acrylate coating.

5. The multi-layer postcard defined in Claim 1, wherein said releasable adhesive comprises an aqueous latex solution.

6. The multi-layer postcard defined in Claim 5, wherein said aqueous latex solution is a natural latex solution.

7. The multi-layer postcard defined in Claim 2, wherein said paperboard layer second surface includes a gloss-imparting coating thereon.

8. The multi-layer postcard defined in

Claim 1, wherein said paperboard layer is formed to have a thickness of between about 0.010 and 0.050 inches .

9. The multi-layer postcard defined in Claim 1, wherein said paper layer first surface has a matte finish.

10. The multi-layer postcard defined in Claim 1, wherein each of said paperboard layer and said paper layer have a perimeter, and wherein said perimeters are substantially aligned when said paper layer overlies said paperboard layer.

11. The multi-layer postcard defined in Claim 1, wherein said printed material on said first paperboard layer surface is thematically related to said printed material on said second paperboard layer.

12. The multi-layer postcard defined in Claim 1, wherein said printed material on said first and second paperboard layers is directed to a recipe for a comestible preparation.

13. The multi-layer postcard defined in Claim 1, wherein said printed material on said first and second paperboard layers is directed to a geographic or historical landmark.

14. A multi-layer postcard having a releasable inscription surface, comprising: a paperboard layer having opposed first and second surfaces, each of said first and second surfaces including printed material thereon and including a gloss-imparting coating thereon, a paper layer having opposed first and second surfaces, said paper layer being formed of a material suitable for receiving an inscription; and an adhesive layer formed of a releasable adhesive being positioned between said paper layer and said paperboard layer to bond said paperboard layer and said paper layer in overlying relationship, with said second paper surface facing said first paperboard surface and said first paper layer surface being exposed to receive an inscription, said releasable adhesive being selected to have a greater adhesion to said paper layer than to said paperboard layer such that, upon peeling of said paper layer from said paperboard layer, said paperboard layer is essentially free of said adhesive and essentially all of said adhesive remains adhered to said paper layer second surface.

15. The multi-layer postcard defined in Claim 14, wherein said gloss-imparted coating is curable with ultraviolet light.

16. The multi-layer postcard defined in Claim 15, wherein said gloss-imparting coating is an epoxy acrylate coating.

17. The multi-layer postcard defined in Claim 14 , wherein said releasable adhesive comprises an aqueous natural latex solution.

18. The multi-layer postcard defined in Claim 17, wherein said aqueous latex solution is a natural latex solution.

19. The multi-layer postcard defined in Claim 14, wherein said paperboard layer is formed to have a thickness of between about 0.010 and 0.050 inches.

20. The multi-layer postcard defined in Claim 14, wherein said paper layer first surface has a matte finish.

21. The multi-layer postcard defined in Claim 14, wherein each of said paperboard layer and said paper layer have a perimeter, and wherein said perimeters are substantially aligned when said paper layer overlies said paperboard layer.

22. The multi-layer postcard defined in Claim 14, wherein said printed material on said first paperboard layer surface is thematically related to said printed material on said second paperboard layer.

23. A method of forming a multi-layer postcard having a releasable inscription surface, said method comprising the steps of: forming a paperboard layer having opposed first and second surfaces, each of said paperboard first and second surfaces having printed material thereon; forming a paper layer having first and second surfaces, said paper layer first surface being conformed for receiving manual inscription thereon; applying a releasable adhesive layer to the paper layer second surface; and adhering said paperboard layer to said paper layer such that the second paper layer overlies and faces the first paperboard layer; the releasable adhesive, paper, and paperboard being selected so that, upon peeling of the paper layer from the paperboard layer, essentially all of the adhesive comprising the adhesive layer adheres to the paper layer, and the first paperboard layer is essentially free of adhesive.

24. The method defined in Claim 23, further comprising the step of coating the first paperboard layer with a gloss-imparting coating prior to said adhering step.

25. The method defined in Claim 24, further comprising the step of coating the second paperboard layer with the gloss-imparting adhesive.

26. The method defined in Claim 24, further comprising the step of irradiating the gloss-imparting coating with ultraviolet light in a amount and for a duration sufficient to cure the gloss-imparting coating.

27. The method defined in Claim 23, wherein said adhesive is an aqueous natural latex solution.

28. The method defined in Claim 23, wherein said applying step comprising applying the releasable adhesive to the second paper layer surface with a roller.

29. The method defined in Claim 23, wherein said paperboard-forming step includes the step of printing polychromatic images onto the first and second paperboard layer surfaces.

30. The method defined in Claim 23, wherein said paperboard-forming step comprises forming a plurality of paperboard layers substantially simultaneously on a single sheet of paperboard, each of said paperboard layers abutting at least one other paperboard layer.

31. The method defined in Claim 30, wherein said paper-forming step comprises forming a plurality of paper layers substantially simultaneously on a single sheet of paper, each of said paper layers abutting at least one other paper layer.

32. The method defined in Claim 31, further comprising the step of separating each of the plurality of paperboard layers from the single sheet of paperboard after said pressing step.

33. The method defined in Claim 24, further comprising the step of applying a primer coating to the surfaces of the paperboard layer prior to the step of applying a gloss-imparting coating.

34. The method defined in Claim 23, further comprising the step of printing addressee indicia on the paper layer first surface.