Inline manufactured crossfold package and method

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.

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 INVENTION

The packet shown inFIGS. 1 through 3completely encloses a multi-page insert which is supplemented by material from a second web.

FIG. 1is a perspective view of a mailing advertising packet10, taken from one of the printed successive full repeats. It has an outer wrap address panel12which has a printed address13of the addressee. The right folded and closed side14is 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. 2shows the opposite openable side16which has an extended gripping section17, disposed opposite a corresponding gripping section19of the lower back outer wrap envelope panel18. A line of self seal releasable pressure contact adhesive strip20, such as latex, is disposed between the extended gripping sections17and19inwardly of the panel outer edges to close that side of the packet10. The gripping sections17and19are pulled apart to open the packet. The sides22and24of the packet10are sealed by releasable self seal pressure releasable contact adhesive strips23and25disposed along the side edges on the inside surface of the outer wrap envelope address and back panels12and18to completely close the packet10.

As shown in the packet cross section ofFIG. 2, the outer edge sections of extended sections17and19are not held together by the adhesive20. 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 at30inFIGS. 2 and 3has many sheets which form a folded booklet. As shown in the open perspective view of the packet10inFIG. 3, the upper center page31and its underlying pages are folded over the lower center page32, and its underlying pages, along the fold line34. Fold line34is the half repeat line for these pages, and is coincident with the fold line14of the outer wrap.

As shown in the cross sectional view of theFIG. 2, as well as the perspective view ofFIG. 1, the packet10is relatively thick because of the number of additional sheets added to the insert30, 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 line34, the free extended edges of the insert pages (as much as25), have a tapered configuration adjacent the adhesive20, and wrap panel openable end sections17and19. This taper adjacent the insert end section will reduce the tendency of the thick insert to separate the adhesive strip20holding the extended wrap sections17and19together.

The perspective-view ofFIG. 4shows two variations that can be made to the closed end packet ofFIG. 1. The packet40and its outer wrap envelope address panel42has both its folded end cut off at43, adjacent to the fold line. And, also, the folded portion of the insert material, (not shown) along line44, and the end of the back outer wrap envelope panel at46. 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 packet40open to permit the packet to be fully pulled open and the insert pieces removed.

Additionally, it is possible to modify the advertising packet10ofFIG. 1at the openable end, by substituting, as shown inFIG. 4, a perforated line48cutting through the wrap panels, inside of the adhesive. The line of perforations extends through both the outer wrap address panel42and the back outer wrap panel. The perforate line48is 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 strip49which opens the packet when the tear off strip is removed.

FIG. 5shows a perspective view of a modified insert booklet50which can be incorporated in the packet, in the same fashion as shown inFIG. 3for the folded booklet30. The folded booklet50ofFIG. 5has plurality of superposed sheet such as51and52which are folded about the half repeat line54. These sheets are stapled together by staples55positioned on the fold line54. The lowermost sheet has panels56and57folded about the half repeat fold line58, which contacts the adhesive strip59. The lower sheet provides outer backing for the booklet and covers the exposed staples55.

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 inFIG. 6.

A large rotatably mounted roll of print paper60feeds a web61through a printing press62, 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 web61is usable for printing of the insert material. The insert portion of the web61bis split off from the wrap ribbon61a, at63, and combined with the insert ribbons in a second web71.

The outer wrap ribbon61a, after the split-off of the insert portion61b, 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, at64. 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 assembly64applying the adhesive to the web.

Remoist glue is applied by the applicator and roller assembly64a, for placing a transverse glue strip on the outer flap of a return envelope configuration (seeFIGS. 12 and 13). The latex adhesive and the remoist glue are dried, as the wrap ribbon passes through the drying oven65. The ink jet imager66applies 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 punch67cuts out the flap for the open envelope ofFIG. 14. The perforating assembly68makes 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 strip49of theFIG. 4configuration.

All of the processing steps, subsequent to the web61passing through the printing press62are applied to the separated outer wrap ribbon61awhich has been separated from the main web, immediately after printing at63.

The separated section of the web61bis 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 web71from the roll70. The superposed insert ribbons61bof the first web61, are brought into position through a turn bar assembly (not shown), underneath and in superposed relation with the superposed insert ribbons from the second web71ato supplement the insert material of web71. The processing and ribboning of the insert section of web61is similar to that of web71. For simplicity of illustration, processing of this insert ribbon group from web61is only shown as line61b.

The separate insert web71from roll70is printed by press72, having the same repeat length as the outer wrap. Web71then passes under an ink jet imager73, which is correlated with address panel imager66, to provide matched outer wrap address and insert addressee data. Web71is separated into ribbons, for a multi-longitudinally folded configuration, and placed in superposed position by the slit and fold stages, schematically shown at74. These operations produce a plurality of superposed insert ribbons, or a common fold ribbon71a.

The ribbons then pass under a staple-stitching assembly75which 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 web71awhich then passes through compensating roller assembly76. The assembly76is manually adjustable to lengthen or shorten the length of web travel. This adjustment keeps the insert web71ain registration with ribbon61aand the cross folder assembly82,83. It is essential that the folder unit make the fold, for both envelope ribbon61aand the insert web71asimultaneously, exactly on the half repeat line of the insert.

Rotary cutter77removes 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 ribbon61a, holds the inserts In in position as they both move to the folder unit82,83. The outer wrap ribbon passes over and around the roller69and downwardly past a manually adjustable movable compensating roller assembly69awhich adjusts the length of travel of the wrap for registering the wrap with the insert web71b. This adjustment also acts to keep the registration of the one half repeat line of the outer wrap ribbon61ain synchronization with the half repeat line of composite web71aand the composite insert pieces, In, passing through cutter77a.

The severed and shortened composite insert pieces, In, then are carried on a conveyor (not shown), and under roller78, and the continuous outer wrap ribbon61a. The outer wrap ribbon61aand the successive matching insert pieces, In, in registration, are then simultaneously passed over the roller80and through nip stapler unit81. Stapler81is 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 assembly82and83. The publication folder assembly folds the outer wrap61aover 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 at84. 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 rollers85press the outer wrap panel adhesive surfaces together, along the side edges. The rollers86press the end adhesive surfaces of the wrap panels together, to close the ends of the packet. The perforating drum87cuts the perforate line228for the tear off strip ofFIG. 20. Perforating drum68cuts perforate line136to permit removal of theFIG. 12letter form from the return order blank printed on the inner side of the outer wrap.

The control of the rotation of the folder cylinders82,83of the folder unit is mechanically controlled by direct mechanical connection88to the operating machinery of the printing press72which 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 assemblies69aand76, 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 blade77aof the cutter77can be adjusted manually for changes in registration, by adjusting the mechanical differential assembly D connected to the mechanical power line89. The power shaft88, is directly connected to the cutter through power line89and Differential D. The power shaft88is thereby interconnected to the cutter77, and cylinder82of the modified publication folder assembly.

The folder assembly elements containing cylinders82and83are 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 ribbon61a.

On folding, the releasable self seal contact adhesive, such as latex, previously applied at64to 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 assemblies84and86.

FIG. 7is a perspective view of a portion of the assembly ofFIG. 6showing 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 ribbon61ahas successive repeats90each of which has a half repeat line91. For registration purposes, a registration mark92is placed along the side edge of the ribbon to control positioning. A photoelectric scanner93, is positioned directly over the line of travel of the successive registration marks92, and sends an electrical output along line93ato 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 roller69and down into the ribbon adjusting section at69a.

The relative speeds of the outer wrap ribbon61aand the composite superposed insert ribbons71aof web71are 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 ribbons71aof web71, overlay added insert web61a, joined underneath web71(detail not shown) prior to the staple or stitching stage79. Web71has successive repeats94, that are aligned with the underlying ribbons, and a half repeat line95. Successive control marks96are disposed along the side edge of the uppermost insert ribbon. The transverse cutout section97will 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 roller76and the cutter77, the electronic scanner98monitors the passage of the control mark96, and transmits a steady signal along line98ato 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 marks92and96is 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 roller69athrough the reciprocating shaft of the compensating assembly T. The movement of the shaft will shorten or lengthen the travel of the outer wrap web61ato adjust the relative position of the half repeat on the webs.

FIG. 7also shows the manner in which the conveyor assembly79supports the insert pieces by a moveable belt79a. The inserts are also held and moved from above by the outer wrap envelope web61b, which passes under the retaining roller78. The positioning mark92on the outer wrap web that passes under the electronic scanner99, immediately before the composite passes over the roller80, also passes the signal along line99afor purposes of controlling the position of the outer wrap and the insert ribbons with respect to the folder tuck blade83aand the receiving groove82aon the folder cylinders82and83. The fold must be made accurately on the aligned half repeat lines of the outer wrap and the insert. The output of the scanner99also controls this adjustment.

The completed and cutoff pieces are shown at84leaving the cylinders82and83of 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 web61, 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 11show variations of envelope configuration of an opened packet, containing a booklet.

An opened completely sealed packet100shown after opening is shown in perspective inFIG. 8. A multiple page booklet carrying center pages101and102are folded about the insert booklet half repeat and fold line104. The pages are held together by staples105. 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 packet100is folded along both the half repeat fold line104of the booklet, and the half repeat fold line106between the outer wrap panels107and108. The booklet end edges103and the side edges are inside and clear of the peripheral self seal releasable contact adhesive strip109on the inner surface outer edges of the wrap panels107and108.

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 staples105can be simultaneously applied to both the insert sheet and to the outer wrap by stitch assembly81if desired. Consequently, packet100provides 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 insert30ofFIG. 3.

FIGS. 9 and 10show two other wrapped booklet configurations as variations of the wrapped booklet packet100ofFIG. 8.

FIG. 9is a perspective view of an opened booklet packet110, where the booklet sheets or, such as111and113, have side edges112and114aligned with the side edges119of the outer wrap panels to provide a folded packet having two open side edges. The outer wrap panels115and117extend beyond the ends of the booklet sheets or and have releasable self seal contact adhesive strips116and118. When the opposed adhesive strips are pressed together they adhere, closing the packet110, 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. 10shows an alternative configuration to the packet110ofFIG. 9, it is a perspective view of an opened packet120. The open center pages121,123of the booklet120have their end edges flush with the ends of the outer wrap panels125and126. The wrap panels125and126are wider than the booklet center pages121and123and their underlying pages. Along the side edges of the panels125and126there are releasable contact adhesive seal strips126and127along one side. And along the opposite side edge128there is a similar adhesive contact strip129. Both adhesive strips are spaced from the insert side edges, such as122and124, 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. 11and relatedFIGS. 12 and 13illustrate the ability to use the outer wrap panels for a return envelope by the recipient.

Referring toFIGS. 11 and 12, the return mailer packet130encloses superposed multiple sheet folded advertising pieces such as the center sheets131and132. Center sheet131and its underlying sheets are disposed over the back panel134of the outer wrap which has two return envelope sections134aand134band an envelope flap section134c. Back panel134is the same size as the address panel135. The half repeat fold line between the center sheets or pages131and132, when it is folded, is aligned with the half repeat fold line136of the outer wrap.

FIG. 12is 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 sections134acontains personalized data, such as a personal order form section137. Subpanel134bhas an order form138. Subpanels134aand134bare folded about line139, as shown inFIG. 13, to form the envelope. The previously used self sealed releasable contact adhesive strips142and143are disposed along the inner side surface of the subpanels134aand134b, and can be reused. They fold on each other as indicated inFIG. 13to adhere and hold the self addressed envelope panels134aand134btogether to provide the envelope140as shown inFIG. 13.FIG. 13is the partially folded back panel of the outer wrap, after it is detached along the perforated and folded half repeat line136. The return envelope flap subpanel134chas a strip of remoist glue141for sealing the return envelope after the flap is folded over along line144.

The inner surface of the address panel135has personalized address data145and146. Self seal, (such as latex) releasable contact, adhesive strips147and148are disposed along its side edges. They initially engage the adhesive strips142and143on 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 strips142and143to subsequently adhere to each other in the return envelope.

FIGS. 14 and 15show an open flap extra insert packet150for receiving samples or extra inserts.FIG. 14is a plan view of the open packet150containing insert pages. Back panel152, part of the outer wrap ribbon has a self seal adhesive such as a latex contact strip153at its free end and a side adhesive strip154along its lower side edge. The half repeat fold line155forms the inner edge of the front address panel156. Address panel156has a strip of releasable contact seal adhesive157, such as latex adhesive adjacent the outer side of panel156. Contact adhesive strip158is disposed adjacent the lower side edge of the address panel156. A closing flap160is disposed along the upper side edge of panel156and has a strip of remoist or self-seal glue161, (applied at67,FIG. 6) for sealing the envelope. Back panel152is folded over the address panel156along their common half repeat line155.

The outer wrap encloses a multiple page insert having a plurality of multiple superposed sheets below the interior centerfold sheets164and166. They are folded about their common half repeat fold line165.

FIG. 15is a perspective view of the folded packet150showing the open envelope after folding, and the outwardly extending flap160. The back and address panels from the outer wrap, forms an open envelope with one end being the fold line along the common repeat lines155and165, 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 strips153and157, 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 strips154and158.

This packet150configuration 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 flap160. Remoist glue is applied to the outer wrap ribbon for flap160before it is die cut, at67ofFIG. 6, to provide prior, to die-cutting, the closing flap160.

The stacked opened packets150are then subsequently filled with a sample or other material, by a separate operation in a conventional mechanical stuffing operation.

FIG. 16illustrates a unique arrangement for the outer wrap generally indicated in170. The front address panel172has a cutout window section174. 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 line175, to rear outer wrap panel176. A strip of self seal releaseable contact adhesive177, 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 panel172.

The rear panel has printed order blank material178to be used by the addressee as a return envelope. The return address of the distributor is printed at179on the rear panel176. The return address179is aligned with the cutout window opening174on 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 at180, has a plurality of sheets181folded along the fold line182. The product catalog180, when folded within the outer wrap, by folder assembly82,83, fits into the outer wrap envelope170. The fold line182is being in contact with the interior surface of outer wrap fold line175.

The periphery of the product catalog is within and immediately adjacent to the contact envelope panel adhesive strips such as strip177of the back panel176. The address section185on the front page of the product catalog180is aligned with the cutout window opening174of panel172. In this manner, the product catalog will have the address of the addressee for mailing. Consequently, the outer wrap170uniquely 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 catalog180, and also allows the addressee to fill in the order information on the rear panel178. 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 address179will show through the cutout window section174of the front address panel172. Both the outer wrap170, and the product catalog180are simultaneously folded by the folder unit.

FIG. 17shows in perspective another type of envelope-booklet assembly, generally indicated at190. A folded booklet191is enclosed by an outer wrap having a front address panel192joined 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 catalog191. The outer panels and the catalog sheets are the same size. Staples193,194pass 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 member198.

FIGS. 18 and 19show a seal arrangement for a booklet-catalog and cover arrangement of the type ofFIG. 17, when the booklet-catalog is very thick. The cover type booklet-catalog generally indicated at200, has an outer cover address and stamp cover address panel202having a closed fold end203and an open closing end204. The back cover panel206as shown inFIG. 19, is joined along the fold line203to the address panel202. The seal end207extends outwardly beyond the end204of panel202. Two paper seal members208are applied to the upper surfaces of the cover panels202and206, at their respective edges204and207to close the catalog for shipping.

FIG. 20is 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 panel222joined along a fold line223to the back envelope panel224at one end. The opposite end225of the packet and the sides of the packet227are held together by a continuous strip of self seal releasable adhesive226which 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 line223by the publication folder. The perforate line228, extending parallel and slightly spaced from the fold line223, extends across the envelope from side to side and completely pierces the envelope itself. A section of the address panel222aand a back envelope panel224aform a tear strip which can be torn from the envelope to remove the fold line section223of the envelope panels as well as the fold line sections230of the folded insert sheets. The perforation line228is 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.