U.S. patent application number 10/610708 was filed with the patent office on 2005-01-06 for certified mailer with return receipt postcard.
Invention is credited to Hutchinson, Wilbur.
Application Number | 20050001021 10/610708 |
Document ID | / |
Family ID | 33552295 |
Filed Date | 2005-01-06 |
United States Patent
Application |
20050001021 |
Kind Code |
A1 |
Hutchinson, Wilbur |
January 6, 2005 |
Certified mailer with return receipt postcard
Abstract
A mailer with return postcard formed from a single sheet of
paper, such as 28# paper, utilizing pressure seal cohesive
material. This is accomplished by applying cohesive material in a
unique pattern and then folding the sheet of paper into a double
V-fold construction.
Inventors: |
Hutchinson, Wilbur; (Saint
George, UT) |
Correspondence
Address: |
NIXON & VANDERHYE, PC
1100 N GLEBE ROAD
8TH FLOOR
ARLINGTON
VA
22201-4714
US
|
Family ID: |
33552295 |
Appl. No.: |
10/610708 |
Filed: |
July 2, 2003 |
Current U.S.
Class: |
229/300 ;
229/316; 229/92.1 |
Current CPC
Class: |
B42D 5/026 20130101 |
Class at
Publication: |
229/300 ;
229/092.1; 229/316 |
International
Class: |
B65D 027/06 |
Claims
What is claimed is:
1. An intermediate for a mailer-type business form, comprising: a
quadrate sheet of paper having parallel top and bottom edges,
parallel first and second side edges perpendicular to the top edge
and first and second faces; at least first, second and third fold
lines parallel to said top and bottom edges dividing said sheet
into at least first, second, third, and fourth panels, said first
and fourth panels being substantially the same size and said second
and third panels being substantially the same size; a first line of
weakness formed in said first, second, third and fourth panels
parallel to and spaced from said first side edge, said first line
of weakness defining a tear off strip providing for ready opening
of a mailer constructed by folding said sheet about said fold
lines; a second line of weakness formed in said first, second,
third and fourth panels parallel to and spaced from second side
edge, said second line of weakness defining a tear off strip
providing for ready opening of a mailer constructed by folding said
sheet about said fold lines; first adhesive areas provided at least
on the second face of one of said first and fourth panels in said
tear off strips, on the second face of at least one of and second
and third panels in said tear off strips and on the first face of
at least one of said third and fourth panels for holding said
second and third panels together said first and fourth panels
together and said third and fourth panels together as an outgoing
mailer when said sheet is double V-folded about said fold lines;
and a second adhesive pattern provided on said second face of at
least one of said first and fourth panels to at least peripherally
adhere reply card defining, mutually facing portions of the first
and fourth panels between said first and second lines of weakness,
whereby said reply card portions of said first and fourth panels
are permanently adhering to define a reply card when said first
through fourth panels are folded along said first through third
fold lines to form an outgoing mailer.
2. An intermediate for a mailer-type business form as in claim 1,
further comprising at least one third line of weakness in said
first panel between said first and second lines of weakness and at
least one fourth line of weakness in said fourth panel between said
first and second lines of weakness to define reply card portions
having at least one dimension less than the corresponding dimension
of the respective panel.
3. An intermediate for a mailer-type business form as in claim 2,
wherein said third and fourth lines of weakness are parallel to
said first and second lines of weakness.
4. An intermediate for a mailer-type business form as in claim 3,
wherein there are at least two third lines of weakness and at least
two fourth lines of weakness so that the reply card is spaced from
each of said first and second lines of weakness in first and fourth
panels.
5. An intermediate for a mailer-type business form as in claim 1,
wherein the second adhesive area is provided about a periphery of
said reply card portions.
6. An intermediate for a mailer-type business form as in claim 1,
further comprising an outgoing address area defined on said first
face of said second panel, said outgoing address area being spaced
from said first and second lines of weakness.
7. An intermediate for a mailer-type business form as in claim 1,
further comprising certified mail indicia on said first face of
said second panel.
8. An intermediate for a mailer-type business form as in claim 1,
further comprising a reply address area defined on said first face
of one of said first and fourth panels, said reply address area
being defined in said reply card portion of said fourth panel.
9. An intermediate for a mailer-type business form as in claim 6,
further comprising an outgoing address area defined on said first
face of said first panel in said reply card portion of said first
panel.
10. A folded mailer including an integral two-ply reply mail piece
which is detachable from said mailer without opening said mailer,
said mailer comprising: a quadrate sheet of paper having parallel
top and bottom edges, parallel first and second side edges
perpendicular to the top edge and first and second faces; at least
first, second and third fold lines parallel to said top and bottom
edges dividing said sheet into at least first, second, third, and
fourth panels, said first and fourth panels being substantially the
same size and said second and third panels being substantially the
same size; a first line of weakness formed in said first, second,
third and fourth panels parallel to and spaced from said first side
edge, said first line of weakness defining a tear off strip
providing for ready opening of a mailer constructed by folding said
sheet about said fold lines; a second line of weakness formed in
said first, second, third and fourth panels parallel to and spaced
from second side edge, said second line of weakness defining a tear
off strip providing for ready opening of a mailer constructed by
folding said sheet about said fold lines; first adhesive areas
provided at least on the second face of one of said first and
fourth panels in said tear off strips, on the second face of at
least one of and second and third panels in said tear off strips
and on the first face of at least one of said third and fourth
panels for holding said second and third panels together said first
and fourth panels together and said third and fourth panels
together as an outgoing mailer when said sheet is double V-folded
about said fold lines; and a second adhesive pattern provided on
said second face of at least one of said first and fourth panels to
at least peripherally adhere reply card defining, mutually facing
portions of the first and fourth panels between said first and
second lines of weakness, whereby said reply card portions of said
first and fourth panels are permanently adhering to define a reply
card when said first through fourth panels are folded along said
first through third fold lines to form an outgoing mailer, said
sheet being folded such that (1) said second surfaces of said first
and fourth panels lie in contact and are adhered together by said
second adhesive pattern to form said two-ply reply mail piece, and
(2) said second surfaces of said second and third panels lie in
contact and are adhered together by said first adhesive pattern and
said first surfaces of said third and fourth panels lie in contact
and are adhered together by said first adhesive pattern.
11. A folded mailer as in claim 10, wherein said reply mail piece
is a two-ply card.
12. A folded mailer as in claim 10, further including at least one
line of weakness provided in at least one of said first and fourth
panels, thereby defining a truncated reply mail piece.
13. A folded mailer as in claim 10, wherein said first and second
adhesive patterns are pressure activatable adhesives.
14. A folded mailer 10, further comprising at least one adhesive
area defined on the second face of the first panel and/or the
second face of the fourth panel, the at least one further adhesive
strip being defined generally parallel to said first/top and bottom
edges of said sheet and being defined intermediate said
third/fourth lines of weakness and said first/second lines of
weakness.
Description
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] Conventional return receipt postcards for certified mail are
created from heavy paper stock having a minimum thickness of about
0.007 inches, such as 91# or 100# tag paper stock, to meet the U.S.
Postal Service (USPS) minimum thickness requirement for a postcard.
Heavy papers are very difficult to process on the most commonly
used laser printers (10-50 ppm range) used in business today.
Furthermore, conventional laser compatible pressure seal certified
mailers require duplex (2-sided) printing which is even more
complex when processing heavy weight papers.
[0002] The present invention provides a USPS certified, registered
or other mailer with return receipt postcard using a single sheet
of paper, for example 28# paper, utilizing pressure seal cohesive
material. This is accomplished by applying cohesive material in a
unique pattern and then folding the sheet of paper into a double
V-fold construction to create the return receipt postcard required
by and meeting the requirements of the USPS certified mail, insured
mail and registered mail. The invention may also be adapted to
create other mailable return postcard such as courtesy or business
reply formats.
[0003] Thus, the invention may be embodied in an intermediate for a
mailer-type business form, comprising: a quadrate sheet of paper
having parallel top and bottom edges, parallel first and second
side edges perpendicular to the top edge and first and second
faces; at least first, second and third fold lines parallel to said
top and bottom edges dividing said sheet into at least first,
second, third, and fourth panels, said first and fourth panels
being substantially the same size and said second and third panels
being substantially the same size; a first line of weakness formed
in said first, second, third and fourth panels parallel to and
spaced from said first side edge, said first line of weakness
defining a tear off strip providing for ready opening of a mailer
constructed by folding said sheet about said fold lines; a second
line of weakness formed in said first, second, third and fourth
panels parallel to and spaced from second side edge, said second
line of weakness defining a tear off strip providing for ready
opening of a mailer constructed by folding said sheet about said
fold lines; first adhesive areas provided at least on the second
face of one of said first and fourth panels in said tear off
strips, on the second face of at least one of and second and third
panels in said tear off strips and on the first face of at least
one of said third and fourth panels for holding said second and
third panels together said first and fourth panels together and
said third and fourth panels together as an outgoing mailer when
said sheet is double V-folded about said fold lines; and a second
adhesive pattern provided on said second face of at least one of
said first and fourth panels to at least peripherally adhere reply
card defining, mutually facing portions of the first and fourth
panels between said first and second lines of weakness, whereby
said reply card portions of said first and fourth panels are
permanently adhering to define a reply card when said first through
fourth panels are folded along said first through third fold lines
to form an outgoing mailer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] These and other objects and advantages of this invention
will be more completely understood and appreciated by careful study
of the following more detailed description of the presently
preferred exemplary embodiments of the invention taken in
conjunction with the accompanying drawings, in which:
[0005] FIG. 1 is a plan view of a first face of an exemplary
intermediate according to the present invention;
[0006] FIG. 2 is a plan view of the second face of the intermediate
of FIG. 1;
[0007] FIG. 3 is a perspective view showing the intermediate of
FIGS. 1 and 2 being folded into a mailer having a return
postcard;
[0008] FIG. 4 is a perspective view showing the removal of the
return postcard of the mailer of FIG. 3 by the postal carrier;
[0009] FIG. 5 is a perspective view showing the opening of the
mailer of FIG. 3 by the end user; and
[0010] FIG. 6 is a perspective view showing the open mailer after
return postcard removal, revealing additional data if duplex
imaging occurred.
DETAILED DESCRIPTION OF THE INVENTION
[0011] An exemplary intermediate for a mailer-type business form
having a return postcard is shown generally by reference number 10
in FIGS. 1 and 2. It includes a quadrate sheet of substantially
opaque paper having parallel top and bottom edges 12,14 and
parallel first and second side edges 16,18, respectively. The side
edges are perpendicular to the top edge. The sheet further defines
first and second faces 20,22, FIGS. 1 and 2, respectively. First,
second and third fold lines 24,26,28 are provided parallel to the
top and bottom edges for dividing the sheet into four panels
30,32,34,36. The first and fourth panels are substantially equal
size and the second and third panels are substantially equal size.
According to an exemplary embodiment, as illustrated, all four
panels are the same size. This allows finishing the document with
simple folding/sealing equipment having only two fold plates; the
benefit being lower equipment cost to customers.
[0012] With reference to the presently preferred, illustrated
embodiment, the first panel 30 is disposed as the top panel of the
form, the second panel 32 is disposed as the second panel of the
form, the third panel 34 is disposed as the third panel of the form
so that the second panel is between the first and third panels, and
the fourth panel 36 is disposed as the bottom panel of the form so
that the third panel is between the second and fourth panels.
[0013] In the presently proposed embodiment, where a return
postcard formed by the first and fourth panels is adapted to be
removed and mailed by, e.g., the postal carrier, fold lines 24 and
28 comprise lines of weakness that facilitate separation of the
return postcard formed by the first and fourth panels (as described
in greater detail below) from the second and third panels. Fold
lines 24 and 28 thus comprise lines of weakness such as perforation
lines or die cut lines. Second fold line 26 may also comprise a
line of weakness such as a perforated line or die cut line, or may
merely be scored or creased to facilitate folding of the mailer
where the mailer is adapted to maintain the second and the third
panels attached. As will be apparent below, the invention is not
limited to the described series and orientations of panels, except
as required by the appended claims.
[0014] The intermediate 10 includes an outgoing address area 40 on
the first face of the second panel 32 as required to meet USPS
requirements. The outgoing address area is of a size and adapted to
receive, e.g., a laser printed address or pre-printed address
label. The outgoing address area can include indicia corners or
other indicator such as a change in texture, tone or color of the
paper to facilitate the determination of the proper location of the
outgoing address. Such indicators, however, are not critical to the
implementation of the invention. Human readable address indicia
such as shown only schematically by indicia 42 in FIG. 1 is
ultimately provided on the intermediate, for example, as it is
passed through a printer. Other human or machine readable indicia
may also be printed or pre-printed on the first face of the second
panel, such as postal address bar coding 44, indicia for postal
stamp application 46 and/or indicia for the sender's return address
48. Because the intermediate is adapted to form a mailer for
certified mail with a return postcard, certified mail indicia 50 is
also provided on the first face of the second panel. Where the
return postcard is provided for courtesy or business reasons, the
certified mailer indicia is omitted or other indicia may be
provided in this region of the envelope.
[0015] In the illustrated embodiment, the first face of the first
panel is also pre-printed according to the type of return postcard
provided. Since the illustrated embodiment provides a certified
mail return receipt, printed indicia corresponding to at least a
portion of the outgoing address indicia 42 is preferably variably
printed on the first face of the first panel as shown at 52. The
first face of the fourth panel is also pre-printed or variably
printed to include reply address indicia 54 in a reply address area
56. Again, the reply address area 56 can include indicia corners or
other indicator as described above with reference to the outgoing
address area 40 to facilitate the determination of the proper
location of the reply address where such indicia is variably
printed.
[0016] In the illustrated embodiment, the indicia 52,54 preprinted
and variably printed on the first face of the first and/or fourth
panels is oriented in the same manner as the outgoing address
indicia 42 provided on the first face of the second panel. This
facilitates the variable printing process, improving the efficiency
and reducing the complexity of processing. It is to be understood,
however, that the indicia, particularly on the first face of the
first and fourth panels, can be inverted from the orientation
shown, if deemed necessary or desirable for effective
implementation of the invention. In this regard, as will be
understood from a consideration of FIGS. 1, 2 and 3, when the
intermediate is folded to form a mailer, the indicia provided on
the first panel first face will be inverted relative to the indicia
provided on the fourth panel first face. If it is preferred to have
the indicia on each face of the return postcard commonly oriented,
either the indicia on the first face of the first panel or the
indicia on the first face of the fourth panel must be inverted so
that when the intermediate is folded, the indicia is commonly
directed on each face of the postcard.
[0017] In the illustrated embodiment, a human or machine readable
indicia may also be printed or pre-printed on the first face of the
fourth panel such as postal address bar coding 58 and indicia for
postal stamp application and/or prepaid postal permit indicia 60.
As noted above, the indicia on any of the panels noted may be
provided upside down relative to the orientation provided in the
illustrated embodiment without departing from this invention.
[0018] In the illustrated and presently preferred embodiment, the
mailer is adapted so that all imaging or personalization is
accomplished on one side of the document in order to minimize the
time required to computer print the form. Thus, the area 62 on the
first face of the third panel may be reserved as a variable data
space when the mailer is adapted to carry semi-confidential
information and to be simplex printed. In this regard, when the
mailer is formed (FIG. 3), the mailer will not be completely sealed
along the bottom edge defined between the top edge of the first
face of the third panel (at fold line 28) and the bottom edge 14 of
the first face of the fourth panel, so that only non-confidential
or semi-confidential information should be included at 62 on the
first face of the third panel. If the intermediate is duplexed
printed, then the areas 64,66 defined by the second faces of the
second and third panels 32,34 may be variably printed with
additional confidential data as this space is fully enclosed and
sealed when the mailer is formed.
[0019] A first line of weakness 68 is formed in the first through
fourth panels parallel to and spaced from the first side edge 16.
The first line of weakness defines a tear off strip 70 (FIGS. 4-5)
provided for readily opening one side of a mailer constructed by
double V-folding the intermediate about fold lines 24,26 and 28, as
shown in FIG. 3. A second line of weakness 72 is further formed in
the first through fourth panels parallel to and spaced from the
second side edge 18. The second line of weakness defines a tear off
strip 74 provided for ready opening of the other side of the mailer
constructed by double V-folding the intermediate about fold lines
24-28.
[0020] In the illustrated embodiment, the first and fourth panels
are adapted to together define a return postcard. To this end, at
least a portion of the first panel is adhered to at least a portion
of the fourth panel so that the mutually attached portions of the
first and fourth panels each comprise one ply or layer of the
postcard. While the entire panel area between lines of weakness
68,70 may define a reply card/mailer, in general this panel area
will be larger than a postcard, so that at least one line of
weakness is preferably provided in each of the first and fourth
panels to provide a truncated panel portion as a reply postcard.
Thus, in a preferred embodiment, at least one third line of
weakness 76,78 is formed in the first panel parallel to and spaced
from the first and second side edges 16,18 and at least one fourth
line of weakness 80,82 is formed in the fourth panel parallel to
and spaced from the first and second side edges 16,18 to define a
return postcard 84 having a width less than the width of the mailer
between lines of weakness 68 and 72. In the illustrated embodiment,
the postcard 84 is centered with respect to the mailer so that
there are two third lines of weakness 76 and 78. In the alternative
the postcard may be right or left justified so that one ply or
layer of the postcard is defined between one third line of weakness
78 or 76 and one of the lines of weakness 68 or 72, respectively,
and the other ply or layer of the postcard is defined between one
fourth line of weakness 82 or 80 and one of the lines of weakness
68 or 72, respectively.
[0021] The intermediate further comprises a first plurality of
adhesive patterns provided along at least some of the edges of the
panels for holding the first through fourth panels together in the
outgoing mailer configuration when the sheet is double V-folded
about fold lines 24,26,28, as illustrated in FIG. 3. In the
illustrated embodiment, the first adhesive patterns include
elongated strips 86 provided on the second face of the first and/or
fourth panels and on the second face of the second and/or third
panels in tear off strips 70,74. The first plurality of adhesive
patterns further include elongated strips 88 provided on the first
face of the third and/or fourth panels in the tear off strips 70,74
to hold the third and fourth panels in opposed facing relation in
the folded configuration. As illustrated, the first adhesive
patterns may also include adhesive strip(s) 92 on the second face
of the first panel and/or the second face of the fourth panel
adjacent the top and bottom edges, respectively, of the
intermediate, between the at least one third line of weakness 76,
78 and the adjacent line of weakness 68, 72 and between the at
least one fourth line of weakness 80,82 and the adjacent line of
weakness 68, 72.
[0022] The adhesive patterns preferably also include a second
plurality of adhesive patterns for forming the return postcard from
the first and fourth panels. In the illustrated embodiment, the
second plurality of adhesive patterns comprise adhesive strips 90
provided around the perimeter of at least one of the postcard parts
defined by lines of weakness 76,78,80,82 (and/or 68, 70 if the
postcard is right or left justified), fold lines 24,28 and the top
and bottom edges 12,14 of the intermediate. Where cohesive is
provided, such patterns 90 are provided on the second face of each
of the first and fourth panels as in the illustrated embodiment. It
is to be understood that as an alternative to or in addition to
strips about the perimeter of the formed card, adhesive may be
provided within said perimeter.
[0023] Preferably the adhesive 86,88 holding the intermediate in
the double V-fold mailer configuration is of substantially
permanent adhesive that is defined by pressure seal adhesive or
cohesive for sealing the mailer upon folding and the application of
suitable pressure to the adhesive region. In the alternative,
however, the adhesive may be re-wettable adhesive, or a pressure
sensitive adhesive covered by a release strip. Also, rather than
continuous elements, the adhesive may be provided as discontinuous
(segmented cohesive pattern) elements and/or in a pattern, shape or
density other than that shown. Thus, the adhesive areas 86,88 may
take any configuration including dash lines, discontinuous dot
configurations and the like. However, it is preferred that the
amount and spacing of such adhesive material be at least sufficient
to allow the mailer to be processed by U.S. Postal Service
automated systems. Furthermore, the second adhesive areas 90 for
defining the return postcard are preferably substantially
continuous to preclude delamination of the return postcard.
[0024] Although not shown, detachable tractor drive strips may be
provided for the intermediate during processing. These strips are
conventional for facilitating handling of the intermediate for
printing or the like during manufacture of the mailer. The strips
are typically provided where the intermediate is in continuous form
so that the top and bottom edges are lines or weakness between
longitudinally adjacent intermediates. During normal processing,
such strips (not shown) are slit off at an appropriate stage to
define the side edges 16,18. In constructing the mailer, after the
intermediate is detached from the adjacent intermediate(s)
continuously printed therewith (if any), and after slitting of any
tractor drive strips (if provided), the intermediate is double
V-folded as illustrated in FIG. 3, typically by conventional
folding equipment, and then run through a suitable sealing machine
(typically conventional equipment, either heat sealing or pressure
sealing having only two folding plates) for activating the first
and second adhesive patterns. Typically, the intermediate shown in
FIGS. 1 and 2 has a length between top and bottom edges of about 14
inches to produce a standard size envelope following double
V-folding.
[0025] When the outgoing addressee receives the mailer, the mailer
is then comprised of first, second and third plys or panels with
the third ply being defined by the adhered first and fourth panels
30, 36 that comprise the return postcard 84, with the second or
bottom face of the second panel 32 in face to face relation with
the second or bottom face of the third panel 34, and further with
the first or top face of the third panel 34 in face to face
relation with the first or top face of the fourth panel 36.
[0026] The return postcard can easily be removed as illustrated in
FIG. 4 by disrupting the postcard along its edges as defined by
line(s) of weakness 78,82 and/or along lines of weakness 76,80
(and/or along lines of weakness 68, 70 if the postcard is right or
left justified). Once the postcard 84 has been separated along its
side edges, it can be removed from the mailer by tearing along
lines of weakness 24,28. In the event the reply postcard 84 is not
to be immediately removed or is a courtesy or business reply card,
as opposed to a return receipt, the mailer may be opened before or
after detachment of the postcard by tearing off tear-off strips
70,74 and then tearing along lines of weakness 24,28. Unfolding the
second and third panels 32,34 will then reveal any information
duplex printed in areas 64,66 on the second or bottom face of the
intermediate, as shown in FIG. 6. Any information printed in area
62 on the first face of the third panel is also revealed by lifting
and/or removing the first and fourth panels, e.g., by tearing along
lines 24,28. The postcard 84 may be then be detached and mailed as
desired by removing the side edge panel(s) 94,96 defined by the
lines of weakness 76,80; 78,82.
[0027] As is apparent from the foregoing, in an embodiment of the
invention, all laser imaging can be in the same orientation for
efficient processing without complex software to rotate image
within a page. Furthermore, the printed document can be finished
using folding/sealing equipment having only two folding plates,
thereby reducing the cost of processing equipment required by the
customer.
[0028] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiment, it is to be understood that the invention is not to be
limited to the disclosed embodiment, but on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the appended claims.
* * * * *