Abstract:
The present invention provides for a mailer suitable for mailing a plurality of disks. This mailer is formed from a unitary sheet of foldable paperboard and is compatible with high-speed, automated mail handling equipment.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       MICROFICHE APPENDIX 
       [0003]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention relates to the field of mailers and envelopes. More specifically, the present invention relates to a mailer for a plurality of disks (e.g., CDs or DVDs) that can be handled by the United States Postal Service (USPS) using high-speed, automated mail handling equipment. 
         [0006]    2. Description of the Related Art 
         [0007]    Digital Versatile Disks (DVDs) and Compact Disks (CDs) are optical media developed to record and play-back audio and audio/visual entertainment materials and to record and play-back data and other information. Many content providers use the DVD and CD formats to make their content available to consumers. These formats have the advantages of having a small form factor while still being able to store large amounts of data. However, the performance of these formats can be adversely affected by physical damage such as minor surface irregularities (such as scratches, smudges, abrasions, and the like) which sometimes cause data loss and/or inoperability. To protect against such physical damage, CDs and DVDs are usually packaged in rigid containers or boxes, commonly referred to as jewel cases (for CDs) and a slightly larger, rigid plastic container commonly used for DVDs. While these packaging systems are adequate and appropriate for retail sale, they are not optimized for shipping small quantities of disks. Frequently, content providers ship small quantities of CDs and/or DVDs in cardboard boxes. While these cardboard boxes provide protection for the included disks, they have the disadvantages of being bulky and expensive. Further, these cardboard boxes are heavy and not subject to processing on the USPS&#39; automated equipment. Thus, postage costs for these types of shipments are significant. 
         [0008]    Many content providers utilize the USPS to ship small quantities of disks to customers. For example, Netflix, Inc., has developed a single-disk packaging system in which a sending package and a return package are provided concurrently. While this system avoids jewel cases, cardboard boxes, and the like, and is designed to be compatible with the USPS high-speed, automated processing equipment, it is designed to accommodate only one disk at a time. 
         [0009]    Accordingly, in this field there is a need for a packaging system that accommodates a plurality of disks and that is compatible with USPS high-speed, automated processing equipment. This packaging system should also be formed from low cost materials, be easily assembled, and be versatile in accommodating different labeling schemes. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    The present invention provides an inexpensive, non-bulky, mailing system for a plurality of CDs and/or DVDs that can be processed on USPS high-speed, automated mail handling equipment, and thus can achieve substantial savings in both packaging and postage costs. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0011]      FIG. 1  is a plan view, showing a preferred embodiment of the mailer of the present invention in an unfolded view. 
           [0012]      FIG. 2  is a plan view, showing a preferred embodiment of the present invention in a partially folded view. 
           [0013]      FIG. 3  is a plan view, showing a preferred embodiment of the present invention in a partially folded view including multiple disks. 
           [0014]      FIG. 4  is a plan view showing a preferred embodiment of the present invention in a fully folded view, ready for mailing. 
           [0000]    
         
           
                 
               
                 
                 
                 
                 
               
             
                 
                     
                 
                 
                   REFERENCE NUMERALS IN THE DRAWINGS 
                 
                 
                     
                 
               
               
                 
                     
                 
               
            
             
                 
                   100 
                   mailer 
                   101 
                   transverse fold line 
                 
                 
                   101A 
                   transverse fold line 
                   102 
                   tab 
                 
                 
                   103 
                   slots 
                   104 
                   tab fold line 
                 
                 
                   105 
                   shoulder 
                   106 
                   upper panel 
                 
                 
                   107 
                   middle panel 
                   108 
                   lower panel 
                 
                 
                   200 
                   adhesive 
                   300 
                   disk 
                 
                 
                   400 
                   seal 
                   401 
                   addressee information 
                 
                 
                   402 
                   return address information 
                 
                 
                     
                 
               
            
           
         
       
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]      FIG. 1  is an unfolded view of the mailer  100  of the present invention. Mailer  100  is comprised of a single sheet of foldable paperboard. Preferably, mailer  100  is formed from paperboard with a basis weight in the range of 28-pounds to 36-pounds. Mailer  100  is divided into three, approximately equal sized panels (upper panel  106 , middle panel  107 , and lower panel  108 ) by transverse fold lines  101  and  101 A. Each of panels  106 ,  107 , and  108  has a front side (shown) and a back side (not shown). Tabs  102  extend from each side of lower panel  108 . Each tab  102  includes a shoulder  105  at each longitudinal end of each tab  102  to facilitate folding of tab  102  along tab fold line  104 . Each tab  102  includes a front side (shown) and a back side (not shown). Slots  103  are preferably diagonal cuts through the paperboard surface of lower area  108 . Preferably, the length of slots  103  is slightly longer than the diameter of the media (typically CDs or DVDs) which slots  103  accommodate. In a preferred embodiment, slots  103  are 5 inches long, which is slightly longer than the diameter of a standard CD/DVD (4.7 inches). 
         [0016]      FIG. 2  shows mailer  100  partially folded. Tabs  102  have been folded along tab fold lines  104  such that the front side of each tab  102  is brought into proximity to the front side of lower panel  108 . Lower panel  108  is folded along transverse fold line  101 A such that the front side of lower panel  108  is brought into proximity to the front side of middle panel  107  (no longer visible). The back sides of tabs  102  are secured to the front side of middle panel  107 , preferably by adhesive  200 . Folding lower panel  108  on top of middle panel  107  creates a pocket (not shown) for receiving materials. Securing the back sides of tabs  102  to the front side of middle panel  107  seals the sides of mailer  100  and allows for slight volumetric expansion of the created receiving pocket. 
         [0017]      FIG. 3  shows mailer  100  with disks  300  inserted through slots  103 . Because slots  103  are only slightly longer than the diameter of disk  300 , the transverse motion of disk  300  in slot  103  is limited. Slots  103  are cut on a diagonal to facilitate easy loading of disks  300 . However, other orientations of slots  103  can also be used (for example, slots  103  can be parallel). Preferably, the length and orientation of slots  103  are selected to prevent disks  300  from shifting more than ½ inch in any direction. 
         [0018]      FIG. 4  shows mailer  100  in its final folded position. Upper panel  106  has been folded along transverse fold line  101  and the front side of upper panel  106  covers and is in contact with the back side of lower panel  108  (not shown). Seals  400  are tabs or wafer seals that prevent mailer  100  from unfolding or opening until seals  400  are removed or cut. Upper panel  106  can be printed with address information  401  and return address information  402 . In its final folded form, mailer  100  preferably has a height of between 5.5 and 6 inches, a length of between 7.25 and 9.75 inches, a thickness of between 0.009 and 0.25 inches, and a weight of not more than 3 ounces. 
         [0019]    Mailer  100  can be manufactured from a single piece of paperboard and, in a preferred embodiment, die cut into the blank shown in  FIG. 1 . Slots  103  are also die cut during this initial step. Next, mailer  100  is machine folded with tabs  102  being folded and glued to middle area  107  as described above. Mailer  100  is then ready for insertion of disks  300 . Once disks  300  are inserted, the final fold may be made by folding upper area  106  over lower area  108 . At this point, seals  400  are applied to ensure the integrity of mailer  100  for processing through the USPS&#39; high-speed, automated mail handling equipment. 
         [0020]    In an alternative embodiment, after the blank for mailer  100  is cut, and before any folding occurs, mailer  100  is run through a printing machine where address information  400  and return address information  401  are printed on the back side of upper panel  106 . Further, advertising, promotional, or other information may be printed on any available side of panels  106 ,  107 , and  108  during this printing process. 
         [0021]    The preceding description contains significant detail regarding the novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given.