U.S. patent application number 14/213137 was filed with the patent office on 2014-07-17 for multi-ply mailer with multiple detachable elements.
The applicant listed for this patent is R.R. Donnelly & Sons. Invention is credited to Gordon Rodgers.
Application Number | 20140197229 14/213137 |
Document ID | / |
Family ID | 43854042 |
Filed Date | 2014-07-17 |
United States Patent
Application |
20140197229 |
Kind Code |
A1 |
Rodgers; Gordon |
July 17, 2014 |
MULTI-PLY MAILER WITH MULTIPLE DETACHABLE ELEMENTS
Abstract
Multi-ply mailer with multiple detachable elements are
disclosed. An example method includes applying adhesive on at least
one of a first face of a first ply of a substrate or a first face
of a second ply of the substrate. The method also includes folding
the substrate about a line of weakness to directly adhere the first
face of the first ply to the first face of the second ply. The line
of weakness separates the first ply from the second ply. The method
also includes forming a pattern of weakness through the first ply
and the second ply to define a first card in the first ply and a
second card in the second ply. The first card is off-set from a
center of the first ply and off-set from edges that define the
substrate and the first line of weakness. The second card is
off-set from a center of the second ply and off-set from the edges
that define the substrate and the first line of weakness.
Inventors: |
Rodgers; Gordon; (Las Vegas,
NV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R.R. Donnelly & Sons |
Chicago |
IL |
US |
|
|
Family ID: |
43854042 |
Appl. No.: |
14/213137 |
Filed: |
March 14, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12578759 |
Oct 14, 2009 |
8720768 |
|
|
14213137 |
|
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|
Current U.S.
Class: |
229/92.8 ;
493/331; 493/397 |
Current CPC
Class: |
B32B 38/04 20130101;
B42D 15/042 20130101; B32B 2429/00 20130101; B32B 38/0004 20130101;
B32B 38/145 20130101; B65D 27/06 20130101; Y10T 156/1051 20150115;
B31D 1/00 20130101; B32B 37/142 20130101 |
Class at
Publication: |
229/92.8 ;
493/397; 493/331 |
International
Class: |
B42D 15/04 20060101
B42D015/04; B31D 1/00 20060101 B31D001/00 |
Claims
1. A postcard, comprising: a substrate comprising a first ply and a
second ply, each of the first ply and the second ply having a first
face and a second face opposite the first face, the first ply
separated from the second ply by a first line of weakness, the
first ply comprising a top edge of the substrate, the second ply
comprising a bottom edge of the substrate, the first and second
plies comprising opposing first and second side edges of the
substrate; an adhesive on at least one of the second face of the
first ply or the second face of the second ply, the adhesive to
adhere the second face of the first ply directly to the second face
of the second ply to form the postcard; a first pattern of weakness
formed in the first ply offset from each of the first line of
weakness, the top edge, the first side edge, and the second side
edge to form a removable first element, the first pattern of
weakness asymmetrically positioned in the first ply; and a second
pattern of weakness formed in the second ply offset from each of
the first line of weakness, the bottom edge, the first side edge,
and the second side edge to form a second removable element, the
second pattern of weakness asymmetrically positioned in the second
ply.
2. The postcard of claim 1, wherein the first element and the
second element is separately removable from the postcard.
3. The postcard of claim 1, wherein a portion of the postcard
between at least one pattern of weakness and the top and bottom
edges and the first and second side edges comprising an first
indicia area, a barcode area, and a postage area.
4. The postcard of claim 1, wherein the first pattern of weakness
and the second pattern of weakness overlap when the substrate is
folded about the first line of weakness.
5. The postcard of claim 4, wherein the first pattern of weakness
and the second pattern of weakness align when the substrate is
folded about the first line of weakness.
6. The postcard of claim 1, wherein the first pattern of weakness
is separated from the top edge a first distance and is separated
from the first line of weakness a second distance, the second
distance greater than the first distance.
7. The postcard of claim 6, wherein the second pattern of weakness
is separated from the bottom edge by the first distance and is
separated from the first line of weakness by the second
distance.
8. The postcard of claim 1, wherein the first pattern of weakness
is separated from the first side edge a first distance and is
separated from the second side edge a second distance, the second
distance greater than the first distance.
9. The postcard of claim 8, wherein the second pattern of weakness
is separated from the first side edge the first distance and is
separated from the second side edge the second distance.
10. The postcard of claim 9, further comprising a postage area
adjacent the second side edge to form the second side edge as a
leading edge in an automatic mail processing system.
11. The postcard of claim of claim 1, wherein the top edge, the
bottom edge, and the first and second side edges are completely
free of any lines of weakness.
12. The postcard of claim of claim 1, wherein the first pattern of
weakness being asymmetrically positioned in the first ply comprises
the first pattern of weakness being off-set from a center of the
first ply.
13. A method, comprising: applying adhesive on at least one of a
first face of a first ply of a substrate or a first face of a
second ply of the substrate; folding the substrate about a line of
weakness to directly adhere the first face of the first ply to the
first face of the second ply, the line of weakness separating the
first ply from the second ply; and forming a pattern of weakness
through the first ply and the second ply to define a first card in
the first ply and a second card in the second ply, the first card
being off-set from a center of the first ply and off-set from the
line of weakness and edges that define the substrate, the second
card being off-set from a center of the second ply and off-set from
the line of weakness and the edges that define the substrate.
14. The method of claim 13, wherein the first card is
asymmetrically positioned in the first ply and the second card is
asymmetrically positioned in the second ply.
15. The method of claim 13, further comprising applying a release
agent between the first card and the second card prior to forming
the pattern of weakness.
16. The method of claim 13, further comprising imaging an address
on a second face of the first ply, the first face opposite the
second face.
17. A method, comprising: forming a first pattern of weakness
through a first ply of a substrate to define a first card; forming
a second pattern of weakness through a second ply of the substrate
to define a second card, the first ply separated from the second
ply by a line of weakness, the first card being off-set from a
center of the first ply and off-set from the line of weakness and
edges that define the substrate, the second card being off-set from
a center of the second ply and off-set from the first line of
weakness and the edges that define the substrate; applying adhesive
on at least one of a first face of the first ply or a first face of
the second ply; and folding the substrate about the line of
weakness to directly adhere the first face of the first ply to the
first face of the second ply.
18. The method of claim 18, wherein the first card is
asymmetrically positioned in the first ply.
19. The method of claim 18, further comprising applying a release
agent on the first card or the second card prior to folding the
substrate.
Description
RELATED APPLICATION
[0001] This patent arises from a continuation of U.S. patent
application Ser. No. 12/578,759, filed Oct. 14, 2009, which is
hereby incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates generally to mailers and more
particularly to a multi-ply mailer with multiple detachable
elements.
BACKGROUND
[0003] Mailers are commonly used for a variety of applications as
an effective way to distribute information and/or promotional
pieces. Mailers oftentimes come in a variety of different
configurations. Such configurations may include a detachable
portion such as, for example, index cards, coupons, etc. These
mailers oftentimes provide cost savings in postage charges by being
sent with bulk rate postage.
[0004] The detachable portion is typically die cut from the mailer,
such that at least one edge of the detachable portion is common to
the edge of the mailer. A recipient may then remove the detachable
portion from the mailer for later use (e.g., coupon redemption,
index card retention, etc.). However, the detachable portion may
become removed during processing by the mail delivery system due to
its location on the mailer's edge. Additionally, the removable
portion is typically limited to a single ply material due to the
significant manufacturing process difficultly and costs associated
with additional plies.
[0005] In other examples, a two-piece mailer assembly has two
separate layers of card stock combined during a manufacturing
process. In this example, the two layers include a release liner
sandwiched therebetween. The release liner is adhered to the
interior surfaces of both of the layers of card stock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1A is a top plan view of an example form showing a
first side of the example form as described herein.
[0007] FIG. 1B is a bottom plan view of the example form of FIG. 1A
showing a second side of the example form.
[0008] FIG. 2 is a top plan view of the example form of FIGS. 1A,
1B disposed in a continuous sheet.
[0009] FIG. 3 illustrates the example form of FIGS. 1A and 1B being
folded along a fold line to form an example mailer.
[0010] FIG. 4 is a top, front perspective view of the example
mailer formed from the example form of FIGS. 1A and 1B.
[0011] FIG. 5 is cross sectional view of the example mailer of FIG.
4, taken along line 5-5.
[0012] FIG. 6 is a top, front perspective view of the example
mailer of FIG. 4, showing the removal of multiple detachable
elements.
[0013] FIG. 7 is cross sectional view of the example mailer of FIG.
6, taken along line 7-7.
[0014] FIG. 8 is cross sectional view of an example mailer showing
an adhesive pattern and a release coating applied over the adhesive
pattern on at least one of example detachable elements.
DETAILED DESCRIPTION
[0015] The following description of the disclosed examples is not
intended to limit the scope of the disclosure to the precise form
or forms detailed herein. Instead, the following description is
intended to be illustrative of the principles of the
disclosure.
[0016] Postcard mailers advantageously provide substantial cost
savings in postage charges over some conventional letters. For
example, the current cost to mail a postcard via the United States
Postal Service (USPS) is less than mailing a regular non-automated
letter. Such cost savings provide an incentive to utilize postcards
for a wide variety of specialized mailings.
[0017] However, postcards must meet certain USPS regulations. One
such regulation requires mailing pieces serving as postcards to
meet particular weight (pounds per surface area) or thickness
requirements. Further regulations require the postcard to have a
certain thickness, weight, and/or size so that the mail piece can
travel through postal sorters or other various postal equipment
without difficulties. Still further, USPS regulations require
specific portions of the postcard (e.g., the barcode area, the
mailing address area, and the postage area) to be free from certain
graphics (e.g., text, images, shading, etc.). For example, current
USPS postcard regulations state that a postcard must have a height
between 3.5 inches and 4.25 inches, a length between 5.0 inches and
6.0 inches, a thickness between 0.007 inches and 0.016 inches, and
a weight of no more than 1 ounce. Furthermore, current USPS
postcard regulations require that a barcode area be free of all
graphics for a minimum of 0.625 inches from the bottom trim line, a
postage area be indicia free for a minimum of 1.5 inches from the
top trim line to 1.25 inches from the right side trim line, and
mailing address area be substantially free of text (other than the
mailing address) for a minimum of 2.75 inches from bottom the
bottom trim line to a minimum of 3.5 inches from the right side
trim line.
[0018] Thus, it is desirable for an outgoing mailer to qualify as a
postcard to realize the postal mail savings for a postcard versus
first class mail. However, such requirements often limit the use of
postcards. For example, the size requirements along with the
indicia-free areas of the mailer may limit the size and number of
detachable portions, making the use of postcards for delivery of
multiple detachable elements more difficult. Furthermore, the
weight requirements may limit the number and type of layers used to
construct the mailer.
[0019] An example mailer described herein satisfies the USPS
postcard regulations and requirements such as, for example, weight,
thickness, and size. To meet USPS postcard thickness requirements
without limiting the type of manufacturing equipment that can be
used, the mailer is formed from a single sheet of paper or stock.
In particular, the example mailer forms described herein are formed
from a single sheet of paper having approximately one-half of the
thickness of the minimum USPS required thickness requirements. In
this manner, the single sheet enables various or custom indicia
such as, for example, personalized customer information, to be
printed on a single side or both sides of the form via for example,
a press machine, a laser printer, a personal printer, an industrial
printer, and/or any other suitable printer.
[0020] Similarly, to meet the USPS postcard weight requirements,
some of the example mailers described herein are formed without a
liner between the mailer layers. For example, in the described
forms, the two formed layers are adhered directly to one another
and the formed detachable elements are capable of being separated
from one another without the use of a liner therebetween.
[0021] Additionally, the example mailer forms described herein
include two panels having multiple detachable elements (e.g., gift
cards, credit cards, business cards, etc.) formed from the two
adjacent panels when the form is folded as an outgoing mailer. For
instance, in one example, the mailer forms include a first panel
and a second panel that when folded are adhered together to form
respective first and second plies of the outgoing mailer. A first
detachable element is formed in the first panel, and a second
detachable element is formed in the second panel. The detachable
elements may be formed by any suitable method, including, for
example, die-cutting, kiss-cutting, perforating, etc. Moreover, the
detachable elements may be formed at anytime prior to, during,
and/or after folding the form as an outgoing mailer. By forming
separable multiple detachable elements within the example mailer
the number of removable portions associated with a given mailer is
maximized, while the space required to form the elements is
minimized, thus meeting the USPS indicia requirements.
[0022] In some examples, the detachable elements are located in
their respective panels such that the elements substantially
overlap when the form is folded as an outgoing mailer. In other
examples, the elements are substantially wholly aligned with one
another. In still other examples, the detachable elements are
offset, such that they do not align with one another when the form
is folded as an outgoing mailer. In each example, the back sides of
the detachable elements are free of adhesive and/or include a
release coating such that when removed from their respective panels
by the user, the detachable elements may be completely separated
from the outgoing mailer and from any other detachable elements.
Once removed, the detachable elements may be retained by the
recipient and/or used for any suitable purposes (e.g., as a coupon,
a gift card, a debit card, etc.).
[0023] Such a configuration also advantageously enables a
manufacturer to print personalized data and/or other information
onto both sides of the postcard as well as both sides of the
detachable elements. Such personalized information may include, for
example, a recipient's name, account number, personal
identification umber (PIN), personalized coupon code, and/or other
information.
[0024] The information in the example mailer form may be any
graphic (e.g., text, image, shading, etc.) human and/or machine
readable, which may be pre-printed on the example form, printed on
the form when the form is passed through a printer such as, for
example, a print press, a laser printer, handwritten on the form,
provided via a label, and/or any combination thereof.
[0025] Advantageously, the mailers disclosed herein are not limited
to a postcard thickness and multiple layers may be included in the
mailers for yielding thicker mailers that provide the consumer with
a higher perceived value. Additionally, a single perforated (e.g. a
CR 80) die will advantageously yield two or more printed and
variable messaged offers on the detachable elements from a single
die. Each of the example detachable elements will be one or two
plies thick, depending upon how many layers the mailer is designed
for and thereby correlate to the possible number of detachable
elements that may be removed. In this instance, a smaller post card
sized mailer can yield a plurality of wallet cards, and variable
data can be concealed with the card backs positioned back-to-back.
Each removable card may have different offers, such as, for
example, one for the recipient, and another for another individual
(e.g., a friend or family member).
[0026] Still further, in some examples, an ultraviolet (UV) varnish
protection or 1-2 laminate protection may be added to the exposed
surface(s) of the detachable elements and/or the surface(s) of the
postcard.
[0027] FIGS. 1A and 1B illustrate an example mailer form 10
described herein. Referring to FIGS. 1A and 1B, the example form 10
is formed from a single sheet of paper 12. In the example, the form
10 has approximately one half the thickness of a postcard meeting
USPS requirements and regulations (e.g., 0.0035 inches thick). In
one example, the form 10 is approximately 8.25 inches in width (W)
by 5.875 inches in length (L). In other examples, the example form
10 may have any other suitable dimensions or sizes. Furthermore,
while illustrated as a separate form, as illustrated in FIG. 2, the
example form 10 may be a portion of a continuous sheet of stock 100
adapted for use in a continuous feed manufacturing machine assembly
(i.e., multiple forms separated by a cutting device during
manufacturing) not shown. Still further, the paper 12 may include a
coating, such as, for example a laminate 13 (see FIGS. 6 and 8)
covering at least a portion of at least one side of the paper 12.
In the illustrated example, the laminate 13 is applied after any
graphics are imprinted on the paper 12, but it will be appreciated
that the graphics may be applied at anytime during the manufacture
of the example form 10. Furthermore, it will be appreciated that if
utilized, the coating may be applied to all or any portion of the
paper 12.
[0028] The example form 10 includes parallel first and second edges
14, 16 and parallel third and fourth edges 18 and 20, respectively.
In this example, the first and second edges 14, 16 are
substantially perpendicular to the third and fourth edges 18, 20.
The form 10 further defines a front face or first side 22 (FIG. 1A)
and a back face or second side 24 (FIG. 1B).
[0029] The example form 10 includes a line of weakness or fold line
26. The example fold line 26 is substantially parallel to the third
and fourth edges 18, 20, and extends substantially transverse to,
and at least partially between the first and second edges 14, 16
for dividing or forming the form 10 into two panels 30, 32. In this
example, the fold line 26 extends substantially the entire distance
between the edges 14, 16 and the fold line 26 is substantially
continuously formed. In other examples, the fold line 26 may extend
less than the entire distance between the first and second edges
14, 16, and/or may be formed by at least two collinear fold lines.
For example, the fold line 26 may be discontinuously formed. Thus,
the first and second panels 30, 32, in combination, define the form
10 prior to folding as an outgoing mailer 300 described below in
connection with FIG. 4. The first and second panels 30, 32 may be
folded onto each other, such as for example, by plow folding,
V-folding, or otherwise.
[0030] In this example, the first and second panels 30, 32 are
substantially the same size (e.g., the same width and length). In
other examples, the panels 30, 32 may be any suitable size such
that when folded, the example form 10 forms a mailer 300 such as,
for example, as described in connection with FIG. 4. The example
first panel 30 is disposed adjacent to the example second panel
32.
[0031] The first and/or second panels 30, 32 may include graphics
including human and/or machine readable indicia that may be
pre-printed on the example form 10, printed when the form 10 is
passed through a continuous feed machine and/or a printer,
handwritten on the form 10, provided via a label, and/or any
combination thereof. Additionally, as described below, the first
and second panels 30, 32 may include personalized information
relating to a particular recipient/customer of the mailer 300
and/or any other suitable information. In some examples, the second
sides 24 of the first and second panels 30, 32 may include
confidential information because, as explained in detail below, the
second sides 24 of the first and second panels 30, 32 are hidden
when the form 10 is folded as the example outgoing mailer 300,
thereby assuring confidentially and show-through protection.
[0032] In this example, the first side 22 of the first panel 30
includes an area for human and/or machine readable indicia such as,
for example, outgoing address information 40, postal bar coding
information 42, return address information 43, and postage 44. The
outgoing address information 40, postal bar coding information 42,
return address information 43, and postage 44, may be directly
imaged on the panel 30, or may be provided by a separate device
such as, for example, a label and/or stamp.
[0033] The first side 22 of the example second panel 30 may include
graphics (e.g., text, images, shading, etc) that are human and/or
machine readable as desired. Such information may include, for
example, advertising material, promotional discounts and/or
rebates, personalized information, etc, or may be left blank.
[0034] The first panel 30 includes a first detachable element 50,
and the second panel includes a second detachable element 52. The
example detachable elements 50, 52 are defined by a pattern of
weakness, such as, for example, perforations 56 formed in the
panels 30, 32. Each of the detachable elements 50, 52 is separable
from the formed mailer 300 along the defined pattern of weakness.
The perforations 56 may be formed by any suitable method,
including, for example, die-cutting, kiss-cutting, perforating,
etc. Moreover, the detachable elements may be formed at anytime
during the manufacturing of the mailer 300, including at any time
prior to, during, and/or after the formation of the mailer 300. In
the illustrated example, the detachable elements are positioned in
the panels 30, 32 such that when the form 10 is folded about the
fold line 26, the detachable elements 50, 52 overlap, and are
substantially aligned with one another. The detachable elements 50,
52 may, however, be located in any suitable location within the
panels 30, 32 and may not overlap and/or align with one another
when the form 10 is folded to form the mailer 300.
[0035] Turning to FIG. 1B, the second face 24 of the example form
10 includes an adhesive pattern 60. The second face 24 of each of
the example detachable elements 50, 52 (e.g., the second face 24 of
the area defined by the perforations 56), however, is free of any
adhesive pattern. The example adhesive pattern 60 is disposed on
the second face 24 of each of the panels 30, 32 such that when the
form 10 is folded about the fold line 26 to form the example mailer
300, the adhesive pattern 60 prevents the mailer 300 from
unfolding. While the example adhesive pattern 60 is shown as
covering substantially the entire face 24 of the example form 10
(minus the second face 24 of the detachable elements 50, 52), in
other examples, the adhesive pattern 60 may include a variety of
different adhesive patterns, including a perimeter adhesive
pattern, a spot adhesive pattern, etc. Furthermore, the adhesive
pattern 60 may be applied to the face 24 such that the adhesive
pattern 60 does not overlap another portion of the adhesive pattern
60 when folded into the mailer 300 (e.g., a single layer of
adhesive when folded).
[0036] In this example, the adhesive utilized in the adhesive
pattern 60 is a permanent adhesive. However, the adhesive pattern
60 may include any suitable adhesive, permanent or otherwise,
including, for example, a contact adhesive, a pressure activatable
adhesive, a light activatable adhesive, a rewettable adhesive, a
heat activated adhesive, and/or any other suitable adhesive or
chemical fastening substance(s).
[0037] FIG. 3 illustrates the example form 10 as it is being folded
about the fold line 26. When folded via, for example, a folding
machine, the folded form 10 may be passed through a roller or other
pressure applying devices that apply sufficient pressure to active
the adhesive on the adhesive pattern 60 to secure or hold the
folded form 10 as the example outgoing mailer 300 shown in FIG. 3.
The example fold line 26 may be any line of weakness, including,
for example, a perforation line, a die cut line, a score, a crease,
etc., to facilitate folding of the example form 10. Furthermore,
the example form 10 described herein is not limited to the
described series and orientations of panels, and may be reversed,
changed, and/or rearranged in any suitable manner. The graphics,
text, or other indicia or information imaged on the first and
second panels 30, 32 may be inverted, moved, exchanged, and/or
otherwise located differently from the orientation shown.
[0038] Still referring to FIG. 3, the example form 10 is shown
being folded about the fold line 26. As shown, when the example
form 10 is folded about the fold line 26, the adhesive pattern 60
of the second side 24 of the first panel 30 is folded into contact
with the corresponding second side 24 of the second panel 32 to
form the mailer 300. At least a portion of the first panel 30 is
adhered to at least a portion of the second panel 32 by the
adhesive pattern 60 so that the mutually attached portions of the
first and second panels 30, 32 each form one ply or layer of the
mailer 300.
[0039] Turning to FIGS. 4-7, the form 10 of FIGS. 1A, 1B, and 3 is
illustrated when folded as the example outgoing mailer 300. The
example outgoing mailer 300 includes a front face 302 and a back
face 304. When the example form 10 is folded as the outgoing mailer
300, the first panel 30 forms the front face 302 and the second
panel 32 forms the back face 304. The area between the perforations
56 define the first detachable element 50, and the second
detachable element 52. As noted above, in this example, the area
between the first detachable element 50 and the second detachable
52 is free of any adhesive pattern 60. The outgoing mailer 300 may
be sent and delivered to the recipient indicated in the outgoing
addressee indicia 40 on the front face 302 via USPS or any other
suitable delivery service.
[0040] Referring to FIGS. 5 and 7, the example outgoing mailer 300
includes a first ply 500, and a second ply 502. The first ply 500
is defined by the laminate 13 and the substrate 12 (e.g., paper)
forming one of the first panel 30 or the second panel 32. The
detachable element 50 is formed by the first ply 500 and the
perforation 56. The second ply 502 is correspondingly defined by
the laminate 13 and the paper 12 forming the other of the first
panel 30 or the second panel 32, while the detachable element 52 is
formed by the second ply 502 and the perforation 56. The first ply
500 is, in this example permanently adhered to the second ply 502
by the adhesive pattern 60. However, as noted, in this example, the
area between the first detachable element 50 and the second
detachable 52 is free of any adhesive pattern 60. As illustrated in
FIG. 5, in one example a trim line or edge 510 may be formed
through the mailer 300 to remove the fold line 26 (shown in phantom
in FIG. 5). The formed mailer 300 may be sent through a suitable
mail delivery system to a recipient.
[0041] To remove the detachable elements 50, 52, the recipient
applies a force sufficient to tear the detachable elements 50, 52
from the outgoing mailer 300 along the perforation 56, such as, for
example by using a finger, pencil, letter opener, or otherwise by
tearing the perforation 56. Because the detachable elements 50, 52
do not have any adhesive between them, the detachable elements are
separately removable as illustrated in FIG. 7. Additionally, the
detachable elements 50, 52 may be removed from the mailer 300
without destroying and/or separating the plies 500, 502, of the
mailer 300 itself.
[0042] Once either or both of the detachable elements 50, 52 are
removed from the mailer 300, the recipient may utilize them in any
suitable fashion. For example, the detachable elements 50, 52, may
be utilized as a coupon, a debit card, a business card, PIN number,
etc. Moreover, because the second faces 24 of each of the
detachable elements 50, 52 are hidden when formed as a mailer 300
(and thus when mailed) and prior to removal by the recipient, the
graphics (e.g., text, images, etc.) imaged on the second faces 24
of the elements 50, 52 may be personal and/or confidential in
nature, and are revealed only when the recipient removes the
elements 50, 52. For added security, the graphics imaged on the
second face 24 of the elements 50, 52 may include additional
security features such as scratch-off coatings, hidden text,
encryption, etc.
[0043] In another example and as shown in FIG. 8, the adhesive
pattern 60 of the mailer 300 may extend over at least a portion of
the second face 24 of at least one of the detachable elements 50,
52. In this instance, at least one of the detachable elements 50,
52 may include a release coating 62 sufficient to prevent the
detachable elements 50, 52 from adhering to the adhesive pattern
60. Accordingly, while the formed mailer 300 may include an
adhesive pattern 60 that extends between at least a portion of the
detachable elements 50, 52, the applied release coating 62 will
allow the two elements 50, 52 to be separated from one another by
the recipient.
[0044] An example linerless two-ply mailer including multiple
detachable elements includes a first ply having opposing top and
bottom edges, opposing first and second side edges substantially
perpendicular to the top edge, a first face and a second face
opposite the first face. The two-ply mailer includes a first
indicia area on the first face of the first ply. The two-ply mailer
includes a second ply substantially the same size as the first ply
and having a first face and a second face opposite the first face.
The two-ply mailer includes a second indicia area on the first face
of the second ply. The two-ply mailer includes an adhesive to
adhere the second face of the first ply directly to the second face
of the second ply to form the linerless mailer. At least one
pattern of weakness is formed in the first and second plies and
offset from each of the top and bottom edges and the first and
second side edges of the first and second ply to form a removable
first element and a removable second element, the first element and
second element being separately removable from the mailer.
[0045] In some examples, the two-ply mailer includes a coating
adhered to at least one of the first face of the first ply or the
first face of the second ply. In some examples, the coating is a
laminate. In some examples, the pattern of weakness is a
perforation. In some examples, the first element and the second
element overlap when the mailer is folded. In some examples, the
first element and the second element substantially align when the
mailer is folded. In some examples, the first element and the
second element are defined by a single pattern of weakness. In some
examples, the first ply and the second ply are permanently adhered
to one another.
[0046] In some examples, the two-ply mailer also includes a graphic
imaged to the second face of at least one of the first ply or the
second ply. In some examples, the mailer is a postcard. In some
examples, the removable first element and the removable second
element are free of adhesive. In some examples, at least one of the
removable first element or the removable second element includes a
release coating applied to the second face. In some examples, the
first ply and the second ply are formed from a single sheet, and
the single sheet is folded about a fold line to form the first and
second ply. In some examples, the fold line is removed after
forming the first and second ply.
[0047] In some examples, two-ply mailer including a plurality of
detachable cards includes a first ply having opposing top and
bottom edges, opposing first and second side edges substantially
perpendicular to the top edge, a first face and a second face
opposite the first face. The two-ply mailer includes a first
indicia area on at least one of the first or second face of the
first ply. The two-ply mailer includes a second ply substantially
the same size as the first ply and having a first face and a second
face opposite the first face. The two-ply mailer includes a second
indicia area on at least one of the first or second face of the
second ply. The two-ply mailer includes an adhesive to adhere the
second face of the first ply directly to the second face of the
second ply to form the linerless mailer. The two-ply mailer
includes a card-shaped pattern of weakness formed in the first and
second plies to form a removable first card and a removable second
card.
[0048] In some examples, the first ply and the second ply are
formed from a single sheet, and wherein the single sheet is folded
about a fold line to form the first and second ply. In some
examples, the two-ply mailer includes a coating adhered to at least
one of the first face of the first ply or the first face of the
second ply. In some examples, the coating is a laminate. In some
examples, the first card and the second card overlap when the
mailer is folded. In some examples, the first card and the second
card substantially align when the mailer is folded. In some
examples, the first play and the second ply are permanently adhered
to one another.
[0049] An example method of forming a two-ply mailer having a first
and second removable cards includes providing a sheet of stock
having a first face and a second face opposite the first face and
creating a fold line dividing the sheet into a first panel and a
second panel substantially the same size as the first panel. The
method also includes imaging indicia on at least one of the first
face or the second face of the sheet and applying an adhesive to
the second face of the sheet. The method includes folding the sheet
along the fold line and adhering the second face of the first panel
to the second face of the second panel. The method includes
creating a pattern of weakness through the first and second panel
offset from the edges of the first and second panel to form a first
removable card and a second removable card. The second face of the
first removable card and the second face of the second removable
card are free of the adhesive. In some examples, the method also
includes coating the first face of the sheet. In some examples, the
coating is a laminate.
[0050] An example method of forming a two-ply mailer having a first
and second removable cards includes providing a sheet of stock
having a first face and a second face opposite the first face and
creating a fold line dividing the sheet into a first panel and a
second panel substantially the same size as the first panel. The
method also includes imaging indicia on at least one of the first
face or the second face of the sheet and applying an adhesive to
the second face of the sheet. The method also includes applying a
release coating over a portion of the adhesive on the second face
of the sheet in at least one of the first panel or the second panel
and folding the sheet along the fold line, such that the release
coating on the first panel aligns with the release coating on the
second panel. The method also includes adhering the second face of
the first panel to the second face of the second panel and creating
a card-shaped pattern of weakness through the first and second
panel and over the release coating to form a first removable card
and a second removable card. In some examples, the method also
includes coating the first face of the sheet. In some examples, the
coating is a laminate.
[0051] Although certain example apparatus and articles of
manufacture have been described herein, the scope of coverage of
this patent is not limited thereto. On the contrary, this patent
covers all apparatus and articles of manufacture fairly falling
within the scope of the appended claims either literally or under
the doctrine of equivalents.
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