Abstract:
A continuous form envelope assembly, wherein a plurality of superimposed plies define mailing envelopes with inserts, including return envelopes therein. Transverse lines of weakening across the plies define the individual envelopes. The return envelope, which is an insert, is defined by two plies, one of which includes a flap formation whereby the return envelope may be closed. The other ply defining the return envelope, includes a protective portion adjacent the flap and which is secured to the outer envelope so that when the return envelope is extracted from the outer envelope, the protective portion remains with the outer envelope.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to continuous business-form assemblies, and more particularly to continuous form envelope assemblies formed of superimposed plies and having insert material including at least one return envelope therein. 
     Representative prior art includes Steidinger U.S. Pat. No. 3,104,799; then Van Malderghem U.S. Pat. No. 3,554,438 and MacDougall, U.S. Pat. No. 3,652,007 
     Recent years have seen a substantial upsurge in the use of business forms of the type that can be placed in the mail with information placed thereon by computer-operated printers or manually-operated tabulators. This upsurge is principally due to the invention disclosed in the above-identified Steidinger patent wherein a totally sealed envelope having insert material already therein can have information inscribed on the envelope and can be placed in the mail without the usual need for stuffing. The elimination of stuffing operations also eliminates the need for correlating insert material with the envelope so that the proper envelope bearing the proper insert material is directed to the correct recipient. 
     Moreover, as disclosed by Steidinger, the insert material may include a return envelope so that all or part of the insert material may be returned to the sender of the original envelope in the enclosed return envelope. 
     Naturally, such advantages have strongly commended the use of structures made according to the teaching of Steidinger. A variety of structures have evolved which include return envelopes. Frequently, the return envelope is made using a pressure sensitive transfer adhesive as the flap sealing adhesive. This adhesive strip is protected by a removable backing which must be removed by the recipient prior to sealing the return envelope. In other instances, the ply forming the side of the return envelope other than that bearing the flap is provided with a removable chip which overlies the adhesive for ease of manufacture and which may provide a measure of protection for the adhesive. In this case, rather than removing a piece of tape to expose the adhesive, the chip must be removed so as to enable the flap to be moistened and folded over for sealing of the return envelope. 
     Heretofore, such means have generally been desirable principally in terms simplifying the manufacture of the form and, to a lesser extent, in precluding the adhesive on the flap of the return envelope from adhering, due to moisture conditions in the mail or in storage, to the interior of the original mailer, thereby precluding easy removability of the return mailer. However, the desirability of providing such means introduces an undesirability in terms of requiring the recipient to perform an otherwise unnecessary operation in terms of removing the chip or the adhesive-protecting tape. The undesirability is enhanced in the construction wherein a chip is employed in that, if directions are not strictly adhered to, the recipient may inadvertently remove the flap of the return envelope rather than the chip. 
     SUMMARY OF THE INVENTION 
     It is the principal object of the invention to provide a new and improved continuous form envelope assembly having insert material in the form of a return envelope. More specifically, it is the object of the invention to provide such an envelope wherein the adhesive on the flap of a return envelope within the mailer is protected until such time as the mailer is opened and does not require the recipient to perform a positive act to remove the protection for such adhesive. 
     An exemplary embodiment of the invention achieves the foregoing object in a construction including a plurality of superimposed plies defining a continuous business form envelope assembly. The outermost ones of the plies define the front and back of mailers while intermediate plies define insert material within the mailers. Transverse lines of weakening across the plies provide for separation of the assembly into individual envelopes for mailing purposes. 
     Two of the intermediate plies define return envelopes. One such ply includes a flap having an adhesive of the moistenable type facing the other intermediate ply. The other intermediate ply includes a chip aligned with the adhesive-bearing flap which chip is loosely attached to the remainder of the ply, the remainder defining the other side of the return envelope. The chip is secured to the outer envelope such that, upon opening the mailer to extract the return envelope, the chip remains with the outer envelope, while the return envelope is easily pulled away from the chip due to the loose connection. As a result, when the original mailer is opened, the adhesive is automatically exposed so as to eliminate the need for the removal of a tape or a chip by the user. 
     According to the preferred embodiment, the return envelope is a top-opening envelope and the chip is L-shaped with the base thereof secured, as by a glue line, to the outer envelope. 
     Other objects of the invention will become apparent from the following specification taken in conjunction with the accompanying drawings. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a continuous form envelope assembly made according to the invention; 
     FIG. 2 is an exploded view of the various components defining an individual envelope in the assembly; and 
     FIG. 3 is a schematic illustrating the relative dimensions of the various plies comprising an individual envelope to each other and the relationship of the glue line to the various components. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A continuous business form envelope assembly is illustrated in FIG. 1 and is folded in a zig-zag stack, generally designated 10, as is conventional. The assembly includes a plurality of individual envelopes 12 which are defined by transverse lines of weakening 14, normally in the form of perforations, extending across the plies defining the assembly. Running longitudinally of the plies are removable control punch margins 16 as is well known. 
     Referring now to FIGS. 2 and 3, an individual envelope 12 in the assembly will be described. It is to be understood that all of the envelopes are identical, are formed of elongated plies, and are separated by the lines of weakening 14. A first ply is designated 18 and may serve as the so-called record ply as is well known in the art. At its opposite longitudinal edges, it is provided with the control punch margins 16 having a plurality of pin-feed holes 20 therein. 
     The immediately subjacent ply 22 defines the front of the individual envelope or mailer in the assembly. Near one side is provided a removable stub 24 which is separable from the remainder of the ply 24 along the line of weakening 25. The stub 24 forms part of a tear strip by which access to the interior of the mailer may be achieved. Finally, the ply 22 is also provided by the control punch margins 16. 
     The next lowermost ply 26 is optional and may be an insert. Through the use of spot carbons or the like (not shown) on the back side of the ply 22, information may be selectively transmitted and imprinted on the insert 26. Means by which such is accomplished are well known in the art and form no part of the instant invention. 
     Ply 26 is die cut at margins 28, 30 and 32 so that when in the completed envelope assembly, those three margins will be free from attachment to the envelope. The fourth margin includes a stub 34 which is in line with the stub 24 and which is separable from the remainder of the insert ply 28 by a line of weakening 36. When assembled, the stub 34 serves as an attaching portion to maintain the insert 28 in a predetermined location within the envelope so as to insure proper alignment during an imprinting process. When the envelope is opened by removal of the stub as is well known, the insert 28 will be free from attachment to the inner envelope and may be easily removed. 
     A further ply 38 defines the front of a return envelope contained within the outer envelope. It, too, may be selectively imprinted upon through the use of spot carbon on the back side of ply 28. Like the ply 28, ply 38 includes die cuts on margins 40, 42 and 44 so that such margins are free from attachment to the interior of the mailer. The ply 38 is also provided with a stub 46 separated from the remainder of the ply 38 by a line of weakening 48. The stub 46 serves as an attaching portion for the ply 38 in the same fashion as the stub 34 serves as an attaching portion for the ply 26. 
     The ply 38, adjacent its upper edge, includes a line of weakening 50 which serves to define a flap 52 for the return envelope. On the back side of the flap 52 is a moistenable adhesive 54 whereby the return envelope may be sealed. 
     If desired, angled cuts 56 may be provided at the corners of the flap 52. 
     A ply 58 defines the back of the return envelope and a covering portion for the adhesive 54. Specifically, the ply 58 includes a return envelope back-defining portion 60 which is separated from the remainder of the ply 58 by transverse slit 62 that aligns approximately with the line of weakening 50 on the ply 38 and a longitudinal partial slit 64. The partial slit 64 is not continuous as at 66 and 68 so as to define small, easily rupturable or breakable tongues interconnecting the back-defining portion 60 with the remainder of the ply 58. 
     The upper and lower margins 70 and 72 of the ply 58 are die cut so as to free the ply 58 from attachment to the mailer along those margins. The margin 74 is also die cut but, as seen in FIG. 3, extends somewhat to the right of the margins 30 and 42 on the plies 26 and 38. 
     As a result, it will be seen that in addition to the return envelope back-defining portion 60, ply 58 includes a generally L-shaped chip 76. The chip 76 in turn defines a covering portion 80, defined by the upright of the L and an attaching portion 81 defined by the base of the L. As can be seen, the covering portion 80 is aligned with the adhesive 54 to cover the same. 
     Finally, the ply 58 includes a stub 78 separated from the remainder of the ply by a line of weakening 82, which stub 78 functions as an attaching portion for the ply 58. 
     A ply 83 defines the back of the mailer. It includes a stub 84 at one side thereof separated from the remainder of the ply by a line of weakening 85. 
     Each envelope 12 comprises the foregoing part and is secured in assembled relation as by glue lines. For example, glue lines 86 (indicated as X&#39;s in FIG. 3) secure the stubs 24, 34, 46, 78 and 84 together to define a single unitary tear-off strip. A transverse glue line 88 on the upper and lower margins of the ply 83 serves to assemble the outer envelope. Specifically, the glue lines 88 secure ply 83 to the ply 22. In addition, along one longitudinal margin, a glue line 90 is provided, which glue line also serves to secure the plies 83 and 22 to each other to define a completely sealed mailer. 
     A glue line 98 extends between the ply 82 and the base of the L-shaped chip 76 to secure the latter to the outer envelope. 
     Finally, to complete the return envelope defined by plies 38 and 58, a glue line 100 extends about three marginal edges up the ply 38 within the line of weakening 48. 
     From the foregoing, it will be appreciated that removal of the tear strip defined by the stubs 24, 34, 46, 78 and 84 will substantially free the contacts from the outer envelope of the mailer. In this respect, the ply 26, if present, will be completely free, while the plies 38 and 58 will be held only by the tongues 66 and 68. The tongues 66 and 68 are so weak that a gentle pull on the return envelope defined by the plies 38 and 58 will result in their severance and the free removal of the return envelope. Due to the presence of the glue line 98, the L-shaped chip 76 will remain within the outer envelope and may be discarded therewith. However, prior to such removal of the return envelope, it will be appreciated that the covering portion 80 has served to cover the adhesive 54 during storage and mailing. Thus, a continuous form envelope assembly made according to the invention eliminates any need for the recipient to remove a chip or an adhesive protective tape prior to sealing the return envelope. It therefore renders a mailer easier to use and eliminates any possibility that the flap 52 on the return envelope would be removed rather than the removable chip.