Abstract:
Two-way disc mailers for mailing DVDs, CDs, video game discs, or other discs from a sender to a recipient via first class mail. The disc mailer provides improved automated mail processing while weighing less than or equal to 1 ounce, including the weight of the disc.

Description:
RELATED APPLICATIONS 
     This is a continuation-in-part of U.S. patent application Ser. No. 10/953,452, filed Sep. 30, 2004 now U.S. Pat. No. 7,798,392, which is related to and claims priority of U.S. Provisional Application No. 60/511,636 entitled “Disc Mailer” filed Oct. 17, 2003. Both applications are incorporated herein by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     This invention relates to two-way delivery containers for discs such as compact discs (“CDs”), video game discs, or digital video discs (“DVDs”). 
     BACKGROUND 
     Envelopes for shipping discs containing digital data are conventionally known and are sometimes referred to as “disc mailers,” even though the shipping may be provided by various delivery service providers. Conventional disc mailers have several drawbacks. For example, some conventional disc mailers do not adequately protect discs during the mailing process, resulting in lost, damaged, or stolen discs. Other conventional disc mailers may exceed certain shipping weight limitations—when weighed with the disc—resulting in increased shipping costs. Other conventional disc mailers use paper that is too flexible, thus resulting in automated processing difficulties and associated delayed processing times, particularly on the return trip of a two-way disc mailer. 
     A two-way disc mailer is designed for shipping a disc via a delivery service to a first recipient and later permitting the first recipient to forward the disc to a second recipient. Two-way disc mailers are popular among DVD rental companies who provide a customer with a rental disc for the customer&#39;s viewing, along with a mailer to send the disc back to the rental company. 
     In one example of a shipping weight limitation, for first-class United States Postal Service (“USPS”) postage, the weight of the two-way disc mailer, with the enclosed disc, must be equal to or less than 1 ounce. The weight of a DVD is approximately 0.62 ounce, which is slightly heavier than the weight of a CD. As a result, the weight of a disc mailer being processed and shipped via USPS first-class mail is preferably less than or equal to about 0.38 ounce. 
     Most delivery items are processed automatically. For automatic processing by the USPS, for example, the dimension of the mailpiece must comply with the USPS aspect ratio regulation. The aspect ratio is expressed as a ratio of length (the direction parallel to the address) divided by height. For example, a postcard 140 mm long by 89 mm high has an aspect ratio of 1.57. An aspect ratio of between 1.3 and 2.5, inclusive, is required for existing USPS automation compatibility. Because discs have a diameter of approximately 120 mm, the height of the disc mailer must be greater than 120 mm, and the length must therefore be greater than 156 mm, to comply with the minimum aspect ratio requirement. As a result, at least 36 mm of length of the disc mailer does not house the disc and may become bent or folded during mail processing, possibly covering the information required for processing, resulting in unnecessary delays. Consequently, it is desirable for the disc mailer to be constructed of material that is less susceptible to bending, while still conforming with the first-class postage weight limitations. 
     Another aspect of delivery item processing is “cancellation,” which can possibly damage the disc enclosed in the mailer. Cancellation involves marking the mailpiece with a mark, such as a postmark that contains the post office name, state, ZIP code, and month, day, and year that the delivery item was canceled. The Advanced Facer Canceller System (“AFCS”) is the primary letter canceling machine used in USPS processing and distribution centers. If during cancellation, the canceling machine strikes the portion of the mailer containing the disc, the disc may be damaged. Generally, the mailpiece is struck anywhere in the area from about 30 mm from the top of the mailpiece, to about 100 mm from the right edge of the mailpiece. Accordingly, it is desirable to locate (that is, position and retain) the disc within the mailer to an area away from where cancellation strike may occur. 
     Further, during processing, some delivery items are marked with a unique identification tag (“ID tag”) so that they can be identified and sorted correctly. The ID tag may be machine-readable and improves both tracking and processing of the marked mail piece. For two-way disc mailers, the ID tag from the initial outbound shipment must not be visible on the return envelope during the second processing. If the ID tag from the initial outbound mailing is visible on the return envelope, the delivery item may be delayed during return processing. 
     Also during processing, the AFCS orients the delivery item with the length side facing up and the short side substantially vertical. As the delivery item is fed through the AFCS, it is transported by belts and pulleys throughout the system. These belts and pulleys apply a frictional force to the delivery item that is substantially parallel to its length. As a result, this frictional force can have the undesirable consequence of inadvertently opening conventional disc mailers that are not completely bound along their length. Accordingly, if the disc mailer comprises a folded flexible sheet of material, it is desirable to locate the folds along the length of the mail piece in order to prevent the AFCS from inadvertently opening or damaging the disc mailer. It may also be desirable to locate the direction of grain of the folded material so that the folds are substantially parallel to the grain, thus minimizing the chance the flexible sheet will tear along the folds. 
     Additionally, because of the required aspect ratio for mail pieces, the disc in a two-way disc mailer with top and bottom sides not completely bound along its entire length may be vulnerable to theft. The disc in this type of conventional mailer may be manipulated out of the mailer without tearing the envelope. Accordingly, locating the folds of a two-way disc mailer along the length-side of the mail piece advantageously provides improved theft deterrence. 
     Accordingly, it is desirable to provide a disc mailer that overcomes the deficiencies found in conventional disc mailers, including those discussed above. 
     SUMMARY OF THE INVENTION 
     Consistent with the invention, systems and methods are provided for improved two-way disc mailers. 
     According to one aspect of the invention, a disc mailer is formed of a flexible sheet, comprising first and second panels separated by a predetermined fold line. The first and second panels are adherable to each other to form a pouch for removably holding a disc. The pouch has a slot through which the disc can pass. A third panel is separated from the second panel by a second predetermined fold line to be folded over the slot and adhered to an outer surface of the disc mailer to cover the slot to form a delivery container having a length and a width. A first address area is located on the outer surface of the third panel and is externally visible when the third panel is folded over the slot. The third panel may comprise a lighter paper stock than the first and second panels. A perforation on the third panel opens the disc mailer to access the disc from the pouch. The perforation allows detachment of the first address area from the disc mailer. 
     Both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a perspective view of a mailer consistent with disclosed embodiments, prior to being folded and adhered to create the finished mailer; 
         FIG. 2  illustrates a folded and adhered mailer of  FIG. 1 , the dotted lines representing the intended position of a pouch and a digital disc within the pouch; 
         FIG. 3  illustrates a reverse side of the mailer of  FIG. 1 ; 
         FIG. 4  illustrates the mailer of  FIG. 1 , prepared for shipment to a first recipient; and 
         FIG. 5  illustrates a perspective view of an alternative embodiment of a mailer consistent with disclosed embodiments, prior to being folded and adhered to create the finished mailer. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Reference will now be made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     A two-way disc mailer  20  is illustrated in  FIGS. 1-3 . Disc mailer  20  is designed to permit a disc  11  ( FIG. 2 ) to be shipped to a first recipient (e.g., from a DVD rental company to a customer), whereby the first recipient can remove the disc  11  for viewing or other use. After the first recipient views or uses disc  11 , the first recipient can forward disc  11  to a second recipient (e.g., back to the DVD rental company) using the same disc mailer  20 . 
     In an exemplary embodiment, disc mailer  20  comprises a flexible sheet of, for example, cardboard or other paper stock that is folded along a first predetermined line  4  ( FIG. 1 ) to form a left panel  1  and a center panel  2 . Inner surface  6  of the left panel  1  is folded along line  4  toward inner surface  7  of center panel  2  to form a volume for holding disc  11 . Inner surface  6  can be glued or otherwise attached to inner surface  7 , for example along lines  32  and  33  ( FIG. 2 ), to form a pouch  12 , including a slot  13 . A disc  11  can be removably inserted into pouch  12  via slot  13  that is formed between left panel  1  and center panel  2  and between lines  32  and  33 . 
     A line  5  separates center panel  2  and right panel  3 . When right panel  3  and center panel  2  are separate pieces, line  5  represents, for example, a glue or other adhesive line. 
     After a disc  11  is inserted into pouch  12 , inner surface  8  ( FIG. 1 ) of the right panel  3  is folded along or adjacent line  5  toward an outer surface  14  ( FIG. 2 ) of left panel  1 , thereby covering slot  13  to secure disc  11  for mailing to the first recipient. Glue or other adhesive is preferably applied to an outer periphery  29  of inner surface  8  of right panel  3 . After left panel  1  is folded to cover center panel  2 , right panel  3  (which is greater in width than left panel  1 ) can be folded along a line  9  closest to periphery  29  to wrap around the mailer and secure inner surface  8  to outer surface  15  of center panel  2 , thereby causing right panel  3  to completely cover outer surface  14  of left panel  1 . Adhesive is preferably also supplied, for example, along an adhesive strip  10  of inner surface  8  of right panel  3 , but adhesive strip  10  is not activated for adherence until the mailer is used to send the disc to the second recipient, as explained below. 
     Preferably, when inner surface  8  of right panel  3  is adhered with adhesive to outer surface  15  of center panel  2 , a first recipient&#39;s address  17  ( FIG. 3 ), which is printed on an outer surface  16  of right panel  3 , is visible, whereas a second recipient&#39;s address  18 , which is printed on outer surface  14  of left panel  1  is not visible. Accordingly, only the first recipient&#39;s address  17  appears on disc mailer  20  when a disc  11  is mailed to the first recipient. The other side of the disc mailer displays outer surface  15  of center panel  2 , which has no printed address and may contain, for example, an advertisement or graphic design. 
     When a disc  11  is shipped to a first recipient in a two-way mailer of the above-described embodiment, the first recipient can open disc mailer  20  by removing part of right panel  3  from disc mailer  20  by, for example, tearing along perforations  9 . The area of right panel  3  between perforations  9  is not adhered to center panel  2 , which allows for easy removal. Once this part of right panel  3  is removed, and because adhesive strip  10  is not initially adhered to other panels, the first recipient can unfold the remaining part of right panel  3  to access disc  11  from slot  13 . 
     After the first recipient views or otherwise uses disc  11 , the first recipient inserts disc  11  back into pouch  12  in preparation for mailing disc  11  and disc mailer  20  to the second recipient. Once disc  11  is in pouch  12 , the first recipient activates adhesive strip  10  (for example, by moistening) and permanently adheres the remaining portion of inner surface  8  of right panel  3  to outer surface  14  of left panel  1 . Adhesive strip  10  may, of course, be activated by other means, for example, by removing a peel-away strip that covers adhesive strip  10 . The first recipient&#39;s address  17  was removed when the first recipient detached part of right panel  3  between perforations  9 . After adhering strip  10  to left panel  1 , the second recipient&#39;s address  18  appears on disc mailer  20  and is no longer obstructed by right panel  3 . The disc  11  can now be mailed to the second recipient. 
     An alternative embodiment is illustrated in  FIG. 5 . Disc mailer  20  can be opened by the first recipient along perforations  9   a , which preferably removes most of right panel  3 . In this embodiment, the width of panel  1  (left) is greater than the width of panel  3  (right). Once a disc  11  is in the pouch ( FIG. 4 ) for mailing to the second recipient, the first recipient covers slot  13  to secure the disc in pouch  12  by folding and permanently adhering an extended portion  1   a  ( FIG. 5 ) of left panel  1  to outer surface  15  of center panel  2 . This embodiment is advantageous because, if an initial ID tag  34  (illustrated, for example, in  FIG. 3 ) is located on outer surface  15 , the extended portion  1   a  of left panel  1  covers the initial ID tag, thus preventing possible delays during return processing to the second recipient. The extended portion  1   a  of left panel  1  can be provided as an alternative to the remaining portion of the right panel that has an adhesive strip  10  discussed above. 
       FIG. 4  illustrates how the two-way disc mailers of the present invention can optionally bias a disc  11  away from cancellation area  19 . Lines  32  and  33 , which demark the outer bounds of pouch  12  and limit movement of disc  11  in the left and right direction according to  FIG. 4 , are suitably offset from cancellation area  19 . More specifically, it is line  33  that prevents disc  11  from entering cancellation area  19 . As previously discussed, disc mailer  20  may be canceled anywhere in cancellation area  19 , which is from about 100 mm from right edge  31  of disc mailer  20  to about 30 mm from top edge  30  of disc mailer  20 . Thus, line  33  is preferably located at least about 100 mm from right edge  31  of disc mailer  20 . Biasing disc  11  in this manner reduces the risk of damage to disc  11  during cancellation. 
     The position of pouch  12  within the mailer is essentially dictated by placement of lines  32  and  33  along the length of the mailer. Pouch  12 , and therefore disc  11 , may be positioned either to the left side of the mailer (as illustrated), or can be place more centrally in the mailer (not shown). This is accomplished by shifting the location of lines  32  and  33  along the length of the mailer. Central placement of the disc allows the mailer to move more stably through the processing equipment. For mailers of certain dimensions, a more central placement of the disc can also prevent the extra length of the mailer in the cancellation area from folding. Such folding may cover information required for processing the mail piece, resulting in unnecessary delays. 
     Additionally, an exemplary embodiment of disc mailer  20  enables a disc  11  to be mailed with first-class postage rates. First class postage rates apply if the total weight of the mailer is less than or equal to 1 ounce. Accordingly, because discs weigh approximately less than or equal to 0.62 ounce, a preferred embodiment of disc mailer  20  weighs less than or equal to 0.38 ounce. In this embodiment and when weighed together with a disc  11 , disc mailer  20  will weigh less than or equal to 1 ounce and qualify for first-class postage rates. 
     Additionally, in an exemplary embodiment of the disc mailer  20 , the predetermined lines  4  and  5  ( FIG. 1 ), are substantially parallel to the longer dimension of the envelope (e.g., top edge  30  ( FIG. 4 )). This minimizes chances that disc mailer  20  might become damaged or otherwise opened during the automatic mail processing. 
     Also in an exemplary embodiment of disc mailer  20 , left panel  1  and center panel  2  comprise a heavier paper stock than right panel  3 . This allows the disc mailer to utilize a heavier card stock for the panels  1 ,  2  that are used for its second mailing (after right panel  3  has been removed) while still remaining within first class postage weight limits. For example, left panel  1  and center panel  2  can comprise a paper stock of heavier than 24-pound craft paper, which provides improved resistance to bending while keeping the mailer within first-class postage rate weight limitations. Panel  3  may then comprise, for example, a paper stock of 24-pound or lighter craft paper. Alternatively, left panel  1  and center panel  2  may be formed of a suitable stock white woven paper, which is generally easier to print on than regular craft paper. Right panel  3  may then comprise a lighter stock of white woven paper. 
     In another exemplary embodiment, the disc mailer  20  comprises opaque paper. Using opaque paper eliminates the need for security printing, which is used for maintaining the confidentiality of the contents of mailer. 
     In an exemplary embodiment of the disc mailer  20 , the predetermined lines  4 ,  5  are substantially parallel to the grain of the flexible sheet. This strengthens the mailer along lines  4 ,  5 , thus minimizing the chance that the mailer might become damaged or otherwise opened during automatic mail processing. 
     In an exemplary embodiment of the two-way disc mailer  20 , the inner surface  8  of the right panel  3  may comprise advertising material and coupons. In particular, coupons may be printed on the inner surface  8  of the right panel  3  between the perforations  9 . 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the structure and methodology of the present invention without departing from the scope or spirit of the invention. Thus, it should be understood that the invention is not limited to the examples discussed in the specification. Rather, the present invention is intended to cover modifications and variations of this invention.