Abstract:
Inline crossfold product and method that will provide substantially more insert sheet material than previous inline crossfold methods, and, additional inline crossfold packet configurations, is provided. A bound crossfold booklet, the equivalent of or a small catalog, which is particularly adapted for large mail distribution is provided. The substantially lower mailing cost of a six by nine inch booklet size, instead of the ordinary letter size catalog, yields substantial savings. Production and handling costs are also minimized since the booklets are bound in the inline process, thereby eliminating separate handling and binding costs, where there is a separate binding and envelope stuffing operation required.

Description:
This application is a continuation-in-part of U.S. patent application Ser. No. 10/158,149 filed on May 31, 2002 now U.S. Pat. No. 6,865,864. 

   FIELD OF INVENTION 
   This invention relates to inline printed and manufactured mailing and advertising items, and particularly to a new type of low cost, inline manufactured crossfold packet and the method of manufacturing it. 
   BACKGROUND OF THE INVENTION 
   Inline printing and manufacture is used for making low cost large volume advertising items, particularly bulk mail pre-addressed envelopes, termed mailers, which contain advertising and solicitation material. 
   Inline manufacture involves printing a web and subsequently performing a number of successive high speed inline processing operations on it, to obtain the intended format and configuration of the final printed item. 
   The first operation is the printing of an envelope and advertising format on a continuous web, within each of a succession of identical printed half repeat sections. Typically, a full repeat section is printed with each revolution of a printing press cylinder. 
   Subsequent operations include applying a pattern of adhesive to the envelope (outer wrap) panels, in each half repeat; adding personalized printing to each successive half repeat section; longitudinally folding the ribboned or folded advertising section of the web, or slitting it into independent ribbons which are then superposed and combined; and, then packaging the printed advertising pieces by longitudinally folding the envelope portion of the web over the advertising material to form envelope packets; and separating, from the web, the formed envelope packets. 
   These operations result in an envelope item, containing printed advertising, produced in one continuous economical operation, ready for mailing. Two identical advertising mailers, in two half repeats, are printed on the flat web surface with each rotation of the printing cylinder. 
   In the conventional inline process, each successive printed one-half repeat or less of the printed web, is the web area limit usable for inline processing. Ordinary inline mailer advertising pieces are usually typical envelope size items having a panel width of four inches and a length of nine inches. This typical letter size envelope limits the size of insert advertising panels, to a smaller size panel and less effective advertising presentation, than the maximum envelope size mailer having a six inch width. But, the six inch width envelope allows for only four advertising insert panels, in a one half repeat, even with the large thirty-six inch inline printing cylinder. 
   Since the inline production process is limited to only a longitudinal folding of the web, it consequently requires two outer wrap envelope panels to be printed side by side in a single one half repeat section of the web. 
   The new type packet, produced by an inline crossfold method, the subject of my co-pending parent application, is not confined to the one-half repeat printing area of the web, and is not limited to longitudinal folding. It recognizes that a crossfold operation can be made as a final step, using a modified signature printing press folder unit used with large printing press equipment. This permits use of a full repeat, if the printed envelope panel configuration is changed, to position the envelope panels end to end in adjacent half repeats. The inline crossfold process introduced to inline printing and fabrication, the ability to produce a finished piece having twice the amount of printed advertisement panels. 
   Although the inline crossfold method substantially increased advertising insert contents and market for inline products, it is limited to a paper content of one repeat. 
   SUMMARY OF INVENTION 
   The present invention is directed to an inline crossfold product and method that will provide substantially more insert sheet material than my previous inline crossfold method, and, additional inline crossfold packet configurations. 
   The invention provides for a bound crossfold booklet, the equivalent of or a small catalog, which is particularly adapted for large mail distribution. The substantially lower mailing cost of a six by nine inch booklet size, instead of the ordinary letter size catalog, is a substantial saving. Production and handling costs are also minimized since the booklets are bound in the inline process, thereby eliminating separate handling and binding costs, where there is a separate binding and envelope stuffing operation required. 
   The additional insert sheet material for the envelope supplied by correlating a second inline processed insert printed web with the insert material of the initial first web. 
   A completely sealed package is also possible with a pre-packaging cutting of the insert pieces, before they are wrapped with the envelope panels, so that they are of less length, and will allow for closure along their end. 
   New inline crossfold envelope configurations are readily opened by the addressee, and they also provide convenient customer order and return mailing features. 
   These and other features add advantages of this invention will become apparent from the following description of the invention. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a closed mailer packet. 
       FIG. 2  is a cross sectional view of the packet of  FIG. 1 . 
       FIG. 3  is a plan view of the opened packet of  FIG. 1 . 
       FIG. 4  is a perspective view of a packet having a trimmed end for providing individual rectangular insert sheets, and also showing a tear off opening section. 
       FIG. 5  is a perspective view of a fold line stapled multi-page booklet and an outer cover. 
       FIG. 6  is a diagram showing the inline processing and crossfold process for making the packet. 
       FIG. 7  is a schematic drawing of the synchronizing assembly for maintaining registration of the half repeat line of the combined web ribbons, and, of the modified publication folder. 
       FIG. 8  is a plan view showing an opened packet containing an opened booklet which is fully enclosed by an outer wrap. 
       FIG. 9  is a plan view showing an opened packet having open sides which contains an open booklet. 
       FIG. 10  is a plan view of an opened packet, containing an opened booklet, and which has two closed sides. 
       FIG. 11  is a plan view of a opened packet of folded sheets having an outer wrap which also is a return envelope. 
       FIG. 12  is a plan view of the outer wrap of  FIG. 11  showing the return envelope format on the inner surface. 
       FIG. 13  shows a partially folded return envelope from the format of  FIG. 12 . 
       FIG. 14  is a plan view of a completed outer wrap blank for a fully enclosed envelope which is adapted to receive additional inserted material after complete fabrication of the packet. 
       FIG. 15  is a perspective view of the outer wrap envelope format of  FIG. 14  after complete manufacture of the packet. 
       FIG. 16  is an exploded perspective view of a packet showing an outer wrap usable as an order and return envelope piece and having an address window. 
       FIG. 17  is a perspective view of an elongated multi-page packet and outer wrap, joined in a multi-page booklet configuration. 
       FIG. 18  is a perspective view of a packet and multi-page booklet folded at one end and closed at the opposite end by an applied wafer seal element. 
       FIG. 19  is a cross sectional view of the packet of  FIG. 18  along lines  19 — 19 . 
       FIG. 20  is a perspective view of a packet openable by tearing off the folded end along a perforated line and which provides multiple separate pieces. 
   

   DESCRIPTION OF THE INVENTION 
   The packet shown in  FIGS. 1 through 3  completely encloses a multi-page insert which is supplemented by material from a second web. 
     FIG. 1  is a perspective view of a mailing advertising packet  10 , taken from one of the printed successive full repeats. It has an outer wrap address panel  12  which has a printed address  13  of the addressee. The right folded and closed side  14  is coincident with the printed one-half repeat line of the repeat. This end of the inline crossfold packet is transversely folded along the half repeat line by the modified publication folder unit. 
   Cross-sectional view,  FIG. 2  shows the opposite openable side  16  which has an extended gripping section  17 , disposed opposite a corresponding gripping section  19  of the lower back outer wrap envelope panel  18 . A line of self seal releasable pressure contact adhesive strip  20 , such as latex, is disposed between the extended gripping sections  17  and  19  inwardly of the panel outer edges to close that side of the packet  10 . The gripping sections  17  and  19  are pulled apart to open the packet. The sides  22  and  24  of the packet  10  are sealed by releasable self seal pressure releasable contact adhesive strips  23  and  25  disposed along the side edges on the inside surface of the outer wrap envelope address and back panels  12  and  18  to completely close the packet  10 . 
   As shown in the packet cross section of  FIG. 2 , the outer edge sections of extended sections  17  and  19  are not held together by the adhesive  20 . These edges are sufficiently wide to permit the package to be grasped between fingertips and then pulled apart. The releasable adhesive allows the wrap panel side to part when the two extended sections are pulled apart. 
   The multi-sheet folded insert generally indicated at  30  in  FIGS. 2 and 3  has many sheets which form a folded booklet. As shown in the open perspective view of the packet  10  in  FIG. 3 , the upper center page  31  and its underlying pages are folded over the lower center page  32 , and its underlying pages, along the fold line  34 . Fold line  34  is the half repeat line for these pages, and is coincident with the fold line  14  of the outer wrap. 
   As shown in the cross sectional view of the  FIG. 2 , as well as the perspective view of  FIG. 1 , the packet  10  is relatively thick because of the number of additional sheets added to the insert  30 , by a full repeat of a second printed web. It will be noted that as a result of the folding of many insert sheets along line  34 , the free extended edges of the insert pages (as much as  25 ), have a tapered configuration adjacent the adhesive  20 , and wrap panel openable end sections  17  and  19 . This taper adjacent the insert end section will reduce the tendency of the thick insert to separate the adhesive strip  20  holding the extended wrap sections  17  and  19  together. 
   The perspective-view of  FIG. 4  shows two variations that can be made to the closed end packet of  FIG. 1 . The packet  40  and its outer wrap envelope address panel  42  has both its folded end cut off at  43 , adjacent to the fold line. And, also, the folded portion of the insert material, (not shown) along line  44 , and the end of the back outer wrap envelope panel at  46 . This cut-off packet will then have a plurality of individual and separate rectangular insert pieces. The packet will then have one side of the packet  40  open to permit the packet to be fully pulled open and the insert pieces removed. 
   Additionally, it is possible to modify the advertising packet  10  of  FIG. 1  at the openable end, by substituting, as shown in  FIG. 4 , a perforated line  48  cutting through the wrap panels, inside of the adhesive. The line of perforations extends through both the outer wrap address panel  42  and the back outer wrap panel. The perforate line  48  is disposed between the end of the insert material and the line of adhesive (not shown) adjacent the outer edges of the wrap panel. This provides a tear off strip  49  which opens the packet when the tear off strip is removed. 
     FIG. 5  shows a perspective view of a modified insert booklet  50  which can be incorporated in the packet, in the same fashion as shown in  FIG. 3  for the folded booklet  30 . The folded booklet  50  of  FIG. 5  has plurality of superposed sheet such as  51  and  52  which are folded about the half repeat line  54 . These sheets are stapled together by staples  55  positioned on the fold line  54 . The lowermost sheet has panels  56  and  57  folded about the half repeat fold line  58 , which contacts the adhesive strip  59 . The lower sheet provides outer backing for the booklet and covers the exposed staples  55 . 
   With inline processing it is possible to make changes in configuration of the closed packet, very simply, without requiring substantial changes in fabricating equipment. The inline processing for producing the packet of the foregoing figures and other variations, is shown diagramatically in  FIG. 6 . 
   A large rotatably mounted roll of print paper  60  feeds a web  61  through a printing press  62 , where a series of successive repeat panels are printed. In this invention, a portion of these printed repeats includes end to end rectangular outer wrap address and back panels, which form the envelope, each panel extending one half repeat length of the repeat along an edge of the web. The remainder of the repeat panels of the web  61  is usable for printing of the insert material. The insert portion of the web  61   b  is split off from the wrap ribbon  61   a , at  63 , and combined with the insert ribbons in a second web  71 . 
   The outer wrap ribbon  61   a , after the split-off of the insert portion  61   b , is a continuing ribbon of successive repeats the width of the wrap panels. Releasable self seal contact adhesive, such as latex, is applied to the under surface of the section of the repeat having the outer wrap panels, at  64 . The glue pattern can be varied to apply adhesive strips along the edges of the inner surface of the wrap address and back panels (i.e., the under surface), or only the transverse edges of the wrap panels, or both, by changing the pattern of the roller assembly  64  applying the adhesive to the web. 
   Remoist glue is applied by the applicator and roller assembly  64   a , for placing a transverse glue strip on the outer flap of a return envelope configuration (see  FIGS. 12 and 13 ). The latex adhesive and the remoist glue are dried, as the wrap ribbon passes through the drying oven  65 . The ink jet imager  66  applies the successive different mailing addresses of the intended recipients, to the upper and outer surface of the printed outer wrap envelope address panels, for all of the succeeding full repeats of the web. The die punch  67  cuts out the flap for the open envelope of  FIG. 14 . The perforating assembly  68  makes a transverse perforate line across each of the outer ends of the outer wrap panels immediately adjacent each end of their repeat to form the tear off strip  49  of the  FIG. 4  configuration. 
   All of the processing steps, subsequent to the web  61  passing through the printing press  62  are applied to the separated outer wrap ribbon  61   a  which has been separated from the main web, immediately after printing at  63 . 
   The separated section of the web  61   b  is an insert section which is either separated into successive superposed ribbons or a multi-folded configuration (not shown), which are then combined with a ribboned or folded second independent printed web  71  from the roll  70 . The superposed insert ribbons  61   b  of the first web  61 , are brought into position through a turn bar assembly (not shown), underneath and in superposed relation with the superposed insert ribbons from the second web  71   a  to supplement the insert material of web  71 . The processing and ribboning of the insert section of web  61  is similar to that of web  71 . For simplicity of illustration, processing of this insert ribbon group from web  61  is only shown as line  61   b.    
   The separate insert web  71  from roll  70  is printed by press  72 , having the same repeat length as the outer wrap. Web  71  then passes under an ink jet imager  73 , which is correlated with address panel imager  66 , to provide matched outer wrap address and insert addressee data. Web  71  is separated into ribbons, for a multi-longitudinally folded configuration, and placed in superposed position by the slit and fold stages, schematically shown at  74 . These operations produce a plurality of superposed insert ribbons, or a common fold ribbon  71   a.    
   The ribbons then pass under a staple-stitching assembly  75  which staples the ribbons together along their half repeat line, to bind them into a booklet, if such a configuration is desired. 
   The superposed insert ribbons, or longitudinally folded insert, form insert web  71   a  which then passes through compensating roller assembly  76 . The assembly  76  is manually adjustable to lengthen or shorten the length of web travel. This adjustment keeps the insert web  71   a  in registration with ribbon  61   a  and the cross folder assembly  82 ,  83 . It is essential that the folder unit make the fold, for both envelope ribbon  61   a  and the insert web  71   a  simultaneously, exactly on the half repeat line of the insert. 
   Rotary cutter  77  removes small transverse sections of the superposed insert ribbons at each end of the full repeat line to separate the web into a successive series of independent sets of superposed shortened sets of inserts, In. The insert In are shorter than the outer wrap panels, to allow space for the self sealed adhesive strips and closure around the end of the insert pieces. 
   The processed outer wrap ribbon  61   a , holds the inserts In in position as they both move to the folder unit  82 ,  83 . The outer wrap ribbon passes over and around the roller  69  and downwardly past a manually adjustable movable compensating roller assembly  69   a  which adjusts the length of travel of the wrap for registering the wrap with the insert web  71   b . This adjustment also acts to keep the registration of the one half repeat line of the outer wrap ribbon  61   a  in synchronization with the half repeat line of composite web  71   a  and the composite insert pieces, In, passing through cutter  77   a.    
   The severed and shortened composite insert pieces, In, then are carried on a conveyor (not shown), and under roller  78 , and the continuous outer wrap ribbon  61   a . The outer wrap ribbon  61   a  and the successive matching insert pieces, In, in registration, are then simultaneously passed over the roller  80  and through nip stapler unit  81 . Stapler  81  is used to join outer wrap and inserts together at their common half repeat fold line, when that is desired. 
   The combined wrap web and inserts then pass to the modified publication folder assembly  82  and  83 . The publication folder assembly folds the outer wrap  61   a  over the set of shortened inserts, along their common synchronized half repeat fold lines. In this operation, the outer wrap, and its corresponding insert are simultaneously folded along their commonly aligned half repeat lines. Each folded packet assembly is then cut off from the end of the composite wrap and insert web, to produce the individual packets generally shown at  84 . The outer wrap address panel and the corresponding back panel thereby provide an envelope for the folded insert where the fold line forms one end of the completed packet. 
   The compression rollers  85  press the outer wrap panel adhesive surfaces together, along the side edges. The rollers  86  press the end adhesive surfaces of the wrap panels together, to close the ends of the packet. The perforating drum  87  cuts the perforate line  228  for the tear off strip of  FIG. 20 . Perforating drum  68  cuts perforate line  136  to permit removal of the  FIG. 12  letter form from the return order blank printed on the inner side of the outer wrap. 
   The control of the rotation of the folder cylinders  82 ,  83  of the folder unit is mechanically controlled by direct mechanical connection  88  to the operating machinery of the printing press  72  which controls the printing and moving the printed web. It should be noted that the folder cylinder circumference may be equal to the repeat length. 
   Small adjustments, when necessary, are made by the ribbon adjusting assemblies  69   a  and  76 , to ensure that each successive fold operation of the modified publication folder, folds along the superposed half repeat line of each set of the superposed wrap panels and their associated insert pieces. Registration must be maintained within close tolerances, about 30 thousandths, of the actual half repeat line of the two incoming composite insert pieces and the wrap ribbon. 
   The cutter blade  77   a  of the cutter  77  can be adjusted manually for changes in registration, by adjusting the mechanical differential assembly D connected to the mechanical power line  89 . The power shaft  88 , is directly connected to the cutter through power line  89  and Differential D. The power shaft  88  is thereby interconnected to the cutter  77 , and cylinder  82  of the modified publication folder assembly. 
   The folder assembly elements containing cylinders  82  and  83  are part of a modified publication folder used with large printing presses used for printing and folding magazine type signatures. The publication folder assembly found in such presses is removed and a web control assembly (not shown) is added, to permit inline feed of the incoming ribbons to the folder unit. The folder assembly takes the end of the combined printed envelope and insert web elements and transversely folds them along the their half repeat line, enclosing them in a clam shell manner, with the insert sheet material In within the two connected ends of the outer wrap panels of ribbon  61   a.    
   On folding, the releasable self seal contact adhesive, such as latex, previously applied at  64  to the under surface along the edges of each of the outer wrap panels, are pressed together to close and seal the envelope packet by the roller assemblies  84  and  86 . 
     FIG. 7  is a perspective view of a portion of the assembly of  FIG. 6  showing in more detail the operational features, as well as an automatic electrical control that automatically synchronizes the half repeat lines of the wrap ribbon, and the composite packet inserts In. 
   The outer wrap ribbon  61   a  has successive repeats  90  each of which has a half repeat line  91 . For registration purposes, a registration mark  92  is placed along the side edge of the ribbon to control positioning. A photoelectric scanner  93 , is positioned directly over the line of travel of the successive registration marks  92 , and sends an electrical output along line  93   a  to a photoelectric registration control unit C. A commercially available control unit is a Baldwin Manufacturing Company WPE Model 230-200. The scanner signal is obtained immediately before the outer wrap ribbon passes over the roller  69  and down into the ribbon adjusting section at  69   a.    
   The relative speeds of the outer wrap ribbon  61   a  and the composite superposed insert ribbons  71   a  of web  71  are maintained by the machinery of the printing presses, which are operated at an identical uniform speed, of from 800 to 1,000 fpm. However, misalignment variations can occur, because of variations in paper stock, moisture content, and other factors, that will slightly displace the half repeat lines of the two webs that are to be joined. Accuracy to within thirty thousandths of an inch must be maintained, even though the webs are traveling at a speed of nearly one thousand feet per minute. 
   The superposed composite ribbons  71   a  of web  71 , overlay added insert web  61   a , joined underneath web  71 (detail not shown) prior to the staple or stitching stage  79 . Web  71  has successive repeats  94 , that are aligned with the underlying ribbons, and a half repeat line  95 . Successive control marks  96  are disposed along the side edge of the uppermost insert ribbon. The transverse cutout section  97  will remove a small piece from each side of the full repeat line on the ribbon. This removed piece will provide a shorter insert sheet group that will fit within the envelope, so that the adhesive at the ends of the outer wrap panels are outside the insert material. 
   Between the manually adjustable compensating roller  76  and the cutter  77 , the electronic scanner  98  monitors the passage of the control mark  96 , and transmits a steady signal along line  98   a  to the photo electronic registration control C. Electronic circuitry compares the succession of incoming signals to determine whether there is any relative displacement between them. Each of the marks  92  and  96  is placed in the same relative position on their respective repeats. The repeats for both webs are of identical length. If there is a change in signal, the output from the registration control C transmits an adjusting signal to the mechanical compensating roller assembly T. Registration of the outer wrap web is controlled by movement of the roller  69   a  through the reciprocating shaft of the compensating assembly T. The movement of the shaft will shorten or lengthen the travel of the outer wrap web  61   a  to adjust the relative position of the half repeat on the webs. 
     FIG. 7  also shows the manner in which the conveyor assembly  79  supports the insert pieces by a moveable belt  79   a . The inserts are also held and moved from above by the outer wrap envelope web  61   b , which passes under the retaining roller  78 . The positioning mark  92  on the outer wrap web that passes under the electronic scanner  99 , immediately before the composite passes over the roller  80 , also passes the signal along line  99   a  for purposes of controlling the position of the outer wrap and the insert ribbons with respect to the folder tuck blade  83   a  and the receiving groove  82   a  on the folder cylinders  82  and  83 . The fold must be made accurately on the aligned half repeat lines of the outer wrap and the insert. The output of the scanner  99  also controls this adjustment. 
   The completed and cutoff pieces are shown at  84  leaving the cylinders  82  and  83  of the publication folder unit. 
   This invention, using two printed webs having the same repeat length, which are accurately synchronized, and have been continuously adjusted for a registration of the half repeat lines with a modified publication folder, makes it possible to enclose the larger amount of insert material, and also to introduce different and varied format designs for the ultimate package, not possible with ordinary inline practices, or with the single web inline crossfold fold process disclosed in my previously filed parent application. 
   This unique inline processing, supplementing the single web inline crossfold capability, provides a bound catalog type booklet ready for mailing. The process makes it possible to completely enclose the insert, containing the material of two webs. The use of two different webs, also makes it possible to provide a high gloss heavy stock printing for the outer wrap web  61 , for the envelope, as well as the cover of the booklet, and its center pages, as well as convenient reusable return envelope configurations. 
   Use of two outer wrap panels in an end-to-end connection at the half repeat line, in a clam shell envelope, has more than four times the number of insert piece capacity as the ordinary longitudinally folded inline envelope, and twice the insert piece capacity of my single inline crossfold process. 
     FIGS. 8 through 11  show variations of envelope configuration of an opened packet, containing a booklet. 
   An opened completely sealed packet  100  shown after opening is shown in perspective in  FIG. 8 . A multiple page booklet carrying center pages  101  and  102  are folded about the insert booklet half repeat and fold line  104 . The pages are held together by staples  105 . The folded multi-page booklet, containing multiple advertising pages or other printed type of material, is then removed. It is a self contained booklet. 
   The packet  100  is folded along both the half repeat fold line  104  of the booklet, and the half repeat fold line  106  between the outer wrap panels  107  and  108 . The booklet end edges  103  and the side edges are inside and clear of the peripheral self seal releasable contact adhesive strip  109  on the inner surface outer edges of the wrap panels  107  and  108 . 
   A modified publication folder does this in a single operation on the incoming end of the composite web for both the inserts, such as the insert booklet, and the outer wrap, simultaneously. It is possible to staple or stitch the booklet sheets or pages together to form a booklet removable from the envelope, or, the staples  105  can be simultaneously applied to both the insert sheet and to the outer wrap by stitch assembly  81  if desired. Consequently, packet  100  provides a readily pulled-open, closed envelope packet mailer with a multiple sheet booklet having a stapled or stitched fold line, instead of the loose separate folded sheets of insert  30  of  FIG. 3 . 
     FIGS. 9 and 10  show two other wrapped booklet configurations as variations of the wrapped booklet packet  100  of  FIG. 8 . 
     FIG. 9  is a perspective view of an opened booklet packet  110 , where the booklet sheets or, such as  111  and  113 , have side edges  112  and  114  aligned with the side edges  119  of the outer wrap panels to provide a folded packet having two open side edges. The outer wrap panels  115  and  117  extend beyond the ends of the booklet sheets or and have releasable self seal contact adhesive strips  116  and  118 . When the opposed adhesive strips are pressed together they adhere, closing the packet  110 , to enclose the folded booklet. The use of two webs makes it possible to have a thick booklet with as many as thirteen sheets on each side of the fold line when thirty-six inch presses are used. 
     FIG. 10  shows an alternative configuration to the packet  110  of  FIG. 9 , it is a perspective view of an opened packet  120 . The open center pages  121 ,  123  of the booklet  120  have their end edges flush with the ends of the outer wrap panels  125  and  126 . The wrap panels  125  and  126  are wider than the booklet center pages  121  and  123  and their underlying pages. Along the side edges of the panels  125  and  126  there are releasable contact adhesive seal strips  126  and  127  along one side. And along the opposite side edge  128  there is a similar adhesive contact strip  129 . Both adhesive strips are spaced from the insert side edges, such as  122  and  124 , a sufficient distance to permit an overlap and closing of the wrap panel edges about the folded booklet. For a six by nine inch mailer, the width of the booklet panels would be about five inches. 
   In addition to the versatility of different configurations, and of different options of sealing the closed booklet, the combining of two separate webs, one for the outer wrap, and the other for the insert material, as noted previously, permits the use of different types of printed paper stocks, such as a high quality gloss for the insert material, and thicker paper stock for the wrap which can act as a cover. 
   Also, it should be noted that part of the wrap web is separated from the wrap ribbon and then subsequently added to the insert ribbons, so that a possibility of high gloss or heavy stock could be introduced, as well, as the center pages of the enclosed booklet. 
     FIG. 11  and related  FIGS. 12 and 13  illustrate the ability to use the outer wrap panels for a return envelope by the recipient. 
   Referring to  FIGS. 11 and 12 , the return mailer packet  130  encloses superposed multiple sheet folded advertising pieces such as the center sheets  131  and  132 . Center sheet  131  and its underlying sheets are disposed over the back panel  134  of the outer wrap which has two return envelope sections  134   a  and  134   b  and an envelope flap section  134   c . Back panel  134  is the same size as the address panel  135 . The half repeat fold line between the center sheets or pages  131  and  132 , when it is folded, is aligned with the half repeat fold line  136  of the outer wrap. 
     FIG. 12  is a plan view of the inner surface of the outer wrap envelope repeat, showing the printing layout of the inner surface of the back panel return envelope. Subpanel sections  134   a  contains personalized data, such as a personal order form section  137 . Subpanel  134   b  has an order form  138 . Subpanels  134   a  and  134   b  are folded about line  139 , as shown in  FIG. 13 , to form the envelope. The previously used self sealed releasable contact adhesive strips  142  and  143  are disposed along the inner side surface of the subpanels  134   a  and  134   b , and can be reused. They fold on each other as indicated in  FIG. 13  to adhere and hold the self addressed envelope panels  134   a  and  134   b  together to provide the envelope  140  as shown in  FIG. 13 .  FIG. 13  is the partially folded back panel of the outer wrap, after it is detached along the perforated and folded half repeat line  136 . The return envelope flap subpanel  134   c  has a strip of remoist glue  141  for sealing the return envelope after the flap is folded over along line  144 . 
   The inner surface of the address panel  135  has personalized address data  145  and  146 . Self seal, (such as latex) releasable contact, adhesive strips  147  and  148  are disposed along its side edges. They initially engage the adhesive strips  142  and  143  on the inside surface of the back panel to hold the address panel and the back panel of the packet together, when the entire packet is initially folded. The publication folder will fold both the insert material and the outer wrap panels about their aligned half repeat fold lines. 
   Opening of the packet to remove the insert material will not affect the ability of the adhesive strips  142  and  143  to subsequently adhere to each other in the return envelope. 
     FIGS. 14 and 15  show an open flap extra insert packet  150  for receiving samples or extra inserts.  FIG. 14  is a plan view of the open packet  150  containing insert pages. Back panel  152 , part of the outer wrap ribbon has a self seal adhesive such as a latex contact strip  153  at its free end and a side adhesive strip  154  along its lower side edge. The half repeat fold line  155  forms the inner edge of the front address panel  156 . Address panel  156  has a strip of releasable contact seal adhesive  157 , such as latex adhesive adjacent the outer side of panel  156 . Contact adhesive strip  158  is disposed adjacent the lower side edge of the address panel  156 . A closing flap  160  is disposed along the upper side edge of panel  156  and has a strip of remoist or self-seal glue  161 , (applied at  67 ,  FIG. 6 ) for sealing the envelope. Back panel  152  is folded over the address panel  156  along their common half repeat line  155 . 
   The outer wrap encloses a multiple page insert having a plurality of multiple superposed sheets below the interior centerfold sheets  164  and  166 . They are folded about their common half repeat fold line  165 . 
     FIG. 15  is a perspective view of the folded packet  150  showing the open envelope after folding, and the outwardly extending flap  160 . The back and address panels from the outer wrap, forms an open envelope with one end being the fold line along the common repeat lines  155  and  165 , and the other end being the adhesively closed opposite end of the packet. The panels are held by the interaction of the matching contact adhesive seal strips  153  and  157 , when they are brought into contact with each other. The lower side edge of the envelope is closed by the interaction of the matching adhesive strips  154  and  158 . 
   This packet  150  configuration is designed in an open envelope configuration to permit receiving additional samples or inserts after the packet is formed, by the inline crossfold assembly. The outer wrap ribbon is initially wider than the envelope width. The outer wrap ribbon is of sufficient width to include the width of the rectangular envelope panels and the closing flap  160 . Remoist glue is applied to the outer wrap ribbon for flap  160  before it is die cut, at  67  of  FIG. 6 , to provide prior, to die-cutting, the closing flap  160 . 
   The stacked opened packets  150  are then subsequently filled with a sample or other material, by a separate operation in a conventional mechanical stuffing operation. 
     FIG. 16  illustrates a unique arrangement for the outer wrap generally indicated in  170 . The front address panel  172  has a cutout window section  174 . The window would be die cut as part of the inline processing. The address panel is joined at one end along the half repeat and fold line  175 , to rear outer wrap panel  176 . A strip of self seal releaseable contact adhesive  177 , usually latex adhesive, is disposed along the rear panel outer edges, and complements a corresponding contact adhesive strip, on the corresponding inner outer edge surface of the front address panel  172 . 
   The rear panel has printed order blank material  178  to be used by the addressee as a return envelope. The return address of the distributor is printed at  179  on the rear panel  176 . The return address  179  is aligned with the cutout window opening  174  on the address panel, so that the return address will show through it after the insert material is removed. 
   A folded multi-sheet product catalog, insert generally indicated at  180 , has a plurality of sheets  181  folded along the fold line  182 . The product catalog  180 , when folded within the outer wrap, by folder assembly  82 ,  83 , fits into the outer wrap envelope  170 . The fold line  182  is being in contact with the interior surface of outer wrap fold line  175 . 
   The periphery of the product catalog is within and immediately adjacent to the contact envelope panel adhesive strips such as strip  177  of the back panel  176 . The address section  185  on the front page of the product catalog  180  is aligned with the cutout window opening  174  of panel  172 . In this manner, the product catalog will have the address of the addressee for mailing. Consequently, the outer wrap  170  uniquely functions as both an initial mailing envelope, as well as a convenient, return envelope where both addresses are preprinted. The reusable adhesive permits the panels to be separated for removal of the product catalog  180 , and also allows the addressee to fill in the order information on the rear panel  178 . The front and rear panels are then brought into contact and held together by the self seal reusable contact adhesive, such as latex. The senders return address  179  will show through the cutout window section  174  of the front address panel  172 . Both the outer wrap  170 , and the product catalog  180  are simultaneously folded by the folder unit. 
     FIG. 17  shows in perspective another type of envelope-booklet assembly, generally indicated at  190 . A folded booklet  191  is enclosed by an outer wrap having a front address panel  192  joined to an underlying back outer wrap envelope panel, not shown. The outer wrap envelope panels are of heavier stock. High gloss finish and high quality printing enables the panels to serve as front and back cover sheets for the catalog  191 . The outer panels and the catalog sheets are the same size. Staples  193 ,  194  pass through both cover and catalog along their aligned half-repeat fold lines. The catalog is held in a closed position along its folded end by elongated wafer glue seal member  198 . 
     FIGS. 18 and 19  show a seal arrangement for a booklet-catalog and cover arrangement of the type of  FIG. 17 , when the booklet-catalog is very thick. The cover type booklet-catalog generally indicated at  200 , has an outer cover address and stamp cover address panel  202  having a closed fold end  203  and an open closing end  204 . The back cover panel  206  as shown in  FIG. 19 , is joined along the fold line  203  to the address panel  202 . The seal end  207  extends outwardly beyond the end  204  of panel  202 . Two paper seal members  208  are applied to the upper surfaces of the cover panels  202  and  206 , at their respective edges  204  and  207  to close the catalog for shipping. 
     FIG. 20  is a perspective view of a packet configuration for a relatively thin mailer packet having multiple single sheet advertising or coupon pieces. The mailer has a rectangular address panel  222  joined along a fold line  223  to the back envelope panel  224  at one end. The opposite end  225  of the packet and the sides of the packet  227  are held together by a continuous strip of self seal releasable adhesive  226  which extends around the periphery of the packet. Disposed withing the packet is a relatively small number of advertising or coupon inserts which were simultaneously folded adjacent and within the fold line  223  by the publication folder. The perforate line  228 , extending parallel and slightly spaced from the fold line  223 , extends across the envelope from side to side and completely pierces the envelope itself. A section of the address panel  222   a  and a back envelope panel  224   a  form a tear strip which can be torn from the envelope to remove the fold line section  223  of the envelope panels as well as the fold line sections  230  of the folded insert sheets. The perforation line  228  is sufficient to enable the removal of the folded sections of both the envelope panels and the folded insert sheets without difficulty. When the tear off section is removed to open the packet, the folded advertising insert or coupon material is converted to a series of individual single sheet pieces. 
   While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention or limits of the claims appended hereto.