Return envelope assembly

In order to ensure the prompt processing of payments of bills with personal checks while using automatic mail opening equipment, a return envelope assembly includes a front panel and a rear panel each having a top edge, a bottom edge, and a pair of side edges. The front and rear panels are integral along their bottom edges about a bottom fold line about which they may be folded so as to have their inner surfaces lie in confronting relation after the envelope is formed from a one piece blank. A side flap is integral with each of the side edges of the front panel about respective side fold lines which are structured such that the side flaps may be folded inwardly to lie between the confronting inner surfaces of the front and rear panels. The side flaps are secured to the inner surface of the rear panel using an adhesive and a closure flap is provided to seal an opening defined by the top edges of the front and rear panels. With this arrangement, the side flaps each have a minimum lateral spacing from an innermost edge to an opposite one of the side fold lines or side edges less than the width of a personal check to prevent it from becoming lodged between one of the side flaps and the rear panel.

FIELD OF THE INVENTION
 The present invention is generally directed to various aspects of envelope
 construction and, more particularly, a return envelope for the payment of
 a bill with a personal check.
 BACKGROUND OF THE INVENTION
 For many years, it has been well known to utilize envelopes for a wide
 variety of purposes. The most common use, of course, is for mailing
 materials that are inserted within the envelope to an intended recipient
 of the materials. Typically, the envelope will be sealed by gluing the
 flap after the materials have been inserted into the envelope.
 Over the years, the construction of envelopes has evolved to meet the
 demands of various applications. For example, it was proposed very early
 in Carroll U.S. Pat. No. 479,555, issued Jul. 26, 1892, to provide a
 combined promissory note and envelope which may be made from a single
 piece of paper. Subsequently, Albree U.S. Pat. No. 863,688, issued Aug.
 20, 1907, proposed a pay envelope and voucher formed from a blank of
 paper. Later, Kosteling U.S. Pat. No. 2,402,821, issued Jun. 25, 1946,
 disclosed a two-way envelope for returning a banking depositor's receipt
 and also making the next deposit. Subsequently, Fromm U.S. Pat. No.
 2,840,295, issued Jun. 24, 1958, disclosed a banking envelope having
 individually separable forms. As for other early examples, see U.S. Pat.
 Nos. 1,265,159; 1,467,803; 1,588,875; 2,196,461; 2,835,434; 2,840,296; and
 2,858,061. While generally representative of the evolution of envelope
 construction, serious problems have nonetheless remained.
 As representative of the more recent evolution of envelope construction,
 see U.S. Pat. Nos. 4,487,360; 4,730,767; 4,730,768; 5,366,146; and
 5,458,284. These patents all relate to various forms of two-way envelopes,
 i.e., envelopes that by way of example may include an outgoing mailer, a
 business return envelope, a payment coupon and a statement or the like.
 With particular reference to the '767, '146, and '284 patents, they each
 disclose a form of what has become commonly known as a bangtail panel
 removable from a return envelope along a tear-off line.
 As shown in the '284 patent, the bangtail panel may typically include
 promotional material which has become commonplace in the mailing of credit
 card statements. As specifically shown in FIG. 18 of the '284 patent, the
 bangtail panel 17b may be separated from the return envelope panel 12b by
 using the perforation line 9b.
 Despite the advancements that have been made as represented by the more
 recent patents, envelopes are known to have seams that are created when
 the flap and panels are folded and adhesively secured. These seams would
 seem to be a relatively by-product of the manufacturing process,
 particularly where the envelope is well formed and the seams are securely
 joined by adhesive. However, even when this is the case, the seams can be
 a problem for the recipient of an envelope having an insert that is to be
 handled by automated equipment.
 In particular, there have been serious problems in connection with the
 processing of return envelopes that are utilized for payment in the credit
 card industry. Each credit card company processes an enormous volume of
 mail every month when credit card holders make payment utilizing a return
 envelope assembly that has been provided for this purpose. Conventionally,
 the credit card holder will return a payment coupon together with a
 personal check that must be removed from the return envelope assembly for
 processing.
 Due to the enormous volume of such payments, the credit card companies must
 be able to utilize automatic mail opening equipment in order to provide
 timely handling for the contents thereof. Such automatic mail opening
 equipment typically causes the top of the return envelope to register and
 be slit, following which each of the sides of the return envelope are
 similarly caused to register and be slit so that the return envelope can
 be opened along the fold line which exists between the front and rear
 panels thereof. After the top and sides sequentially register and are
 slit, the envelope drops into a trough and a vacuum pulls the front and
 rear panels open so that the envelope assumes a generally V-shape.
 At this point in the automated procedure, the front and rear panels of the
 envelope each enter a guide and the inserts (e.g., the payment coupon,
 personal check, etc.) also enter a guide. The guides for the front and
 rear panels maintain them in a generally V-shape whereas the guide for the
 payment coupon/personal check maintains them generally equidistant and
 between the front and rear panels. At a downstream location, a belt grabs
 the inserts, i.e., the payment coupon, personal check, etc., and delivers
 them for processing, and the remainder of the return envelope is
 discarded.
 For credit card companies, the inserts need to be processed at the earliest
 possible moment since the credit card holder may, e.g., be credited with
 payment as early as the date of receipt of the return envelope. It will be
 understood that credit card companies process personal checks worth
 extremely significant amounts in the aggregate and any delay in depositing
 these checks is a critical cost factor. Unfortunately, the time for
 depositing the checks is longer than desirable in view of a problem that
 is well known in connection with the use of automatic mail opening
 equipment to process the return envelopes.
 More specifically, the return envelope is conventionally formed with side
 flaps that are quite small in width and are folded inwardly between the
 front and rear panels. The small size makes sense from one point of view
 inasmuch as minimizing the dimensions of the various portions of the
 return envelope including the side flaps, saves on the cost of materials,
 but there are practical restrictions on the size and relative dimensioning
 of envelopes due to postal regulations which include a minimum width
 requirement as well as a requirement that envelopes be within a certain
 "aspect ratio." As for the aspect ratio, this is the term used for the
 width of an envelope in relation to its height, and the requirement is
 that this must be between 1.3 and 2.5.
 If an envelope is of a size having an aspect ratio outside this range,
 there is a surcharge that is added since it is considered "non-standard
 mail." The same holds true for the minimum width requirement, i.e., for
 any envelope having a width less than 5 inches. As a result, designers of
 envelopes have tried to maintain a balance as to the minimization of
 material and meeting the requirements for standard mail as defined by
 postal regulations.
 In so doing, the return envelopes that have been utilized in most cases by
 credit card companies have assumed a relatively standard configuration.
 This has included providing side flaps of minimum width in envelopes that
 are used by credit card companies and, more specifically, where the
 spacing between the innermost edge of the side flaps to the opposite edge
 of the envelope is greater than the width of a standard personal check,
 i.e., 6 inches. However, the personal check can easily be caught between
 the side flap and the rear panel so that it is not properly processed by
 the automatic mail opening equipment.
 When this occurs, the personal check is drawn with the rear panel by the
 vacuum and then proceeds with the rear panel into its guide rather than
 with the guide for the inserts as intended. To detect this problem, the
 automatic mail opening equipment is provided with a sensor that detects
 the presence of more than a single thickness in the location of the rear
 panel after it has entered its guide. Specifically, the sensor is set to
 look for more than a single thickness in the region of the rear panel
 between the innermost edges of the side flaps. If the check has been
 caught between one of the side flaps and the rear panel due to shifting
 while it has been in transit, the sensor will detect more than a single
 thickness and will shut down the line for manual removal of the envelope.
 In practice, it is understood that some credit card companies have
 experienced shut downs on an average of approximately one out of every 25
 envelopes that pass through the automatic mail opening equipment.
 As previously mentioned, the difficulty is encountered due to the spacing
 between the innermost edges of the side flaps in relation to the opposite
 side edges of the envelope. When that spacing is greater than the width of
 a standard personal check, the check can shift to one side edge as it is
 being transported in the mail and then back again to a point where it
 becomes lodged between one of the side flaps and the rear panel to which
 it is adhesively secured. In fact, and as mentioned, this occurs with such
 great frequency that the automatic mail opening equipment is shut down on
 an average of one out of every 25 envelopes processed.
 The present invention is directed to overcoming one or more of the
 foregoing problems and achieving one or more of the resulting objects.
 SUMMARY OF THE INVENTION
 It is a principal object of the present invention to provide a new and
 improved envelope that overcomes at least some of the problems encountered
 with prior constructions. It is also an object of the present invention to
 provide a return envelope assembly that is fully suited for use with
 automatic mail opening equipment. It is an additional object of the
 present invention to provide a return envelope assembly that prevents
 personal checks from becoming lodged between a side flap and rear panel.
 Accordingly, the present invention is directed to a return envelope
 assembly for the payment of a bill with a personal check wherein the
 return envelop assembly is prepared entirely from a one piece blank that
 includes a front panel and a rear panel each having a top edge, a bottom
 edge, and a pair of side edges. The front and rear panels are integral
 along their bottom edges about a bottom fold line with the front panel
 having an inner surface which lies in confronting relation with an inner
 surface of the rear panel after the envelope is formed. Further, the
 return envelope assembly includes a side flap integral with each of the
 side edges of the front panel about respective side fold lines about which
 the side flaps are folded inwardly to lie in a position between the
 confronting inner surfaces of the front and rear panels after the envelope
 is formed.
 With this construction, the return envelope also includes means for
 securing each of the side flaps to the inner surface of the rear panel so
 as to be integral therewith. It still additionally includes means for
 sealing an opening defined by the top edges of the front and rear panels
 after removal of the extension panel. Moreover, the return envelope
 assembly is such that the side flaps each have a minimum lateral spacing
 in relation to the opposite side of the envelope less than the width of
 the personal check.
 In an exemplary embodiment, the front and rear panels are generally
 rectangular in shape, and the means for closing the opening comprises a
 closure flap integral with the top edge of the front panel. It is also
 advantageous for the means for securing the side flap to comprise a
 permanent adhesive, and for the side flaps to each be formed such that
 they have generally parallel innermost edges thereon. With this
 arrangement, the innermost edges are separated from the opposite side
 edges by the minimum lateral spacing that is less than the width of the
 personal check entirely therealong.
 In a highly preferred embodiment, the minimum lateral spacing between the
 side flaps and the opposite side edges is on the order of approximately at
 least 1/4 inch less than the width of the personal check for the payment
 of the bill. Most advantageously, the minimum lateral spacing is on the
 order of at least approximately five percent less than the width of the
 personal check for the payment of the bill.
 In another respect, the present invention is directed to a bangtail
 envelope assembly for the payment of a credit card bill with a personal
 check wherein the bangtail envelope assembly is prepared entirely from a
 one piece blank. The bangtail envelope assembly is identical in nearly
 every respect to the return envelope assembly previously described with
 the exception that it incorporates a removable bangtail panel wherein the
 bangtail panel and rear panel are integral along their top edges about a
 second fold line. Still more specifically, the second fold line preferably
 comprises a perforated line for separating the bangtail panel from the
 envelope prior to mailing a payment coupon, personal check and the
 bangtail in the envelope.
 With this arrangement, the side flaps each preferably have their free edge
 positioned inwardly of the side edges of the front and rear panels of the
 envelope. The free edges on the side flaps also advantageously span a
 majority of the distance between the top and bottom edges of the front and
 rear panels. Still additionally, the bangtail envelope assembly preferably
 has an aspect ratio of between 1.3 and 2.5 and a minimum width of
 approximately 5 inches.
 Other objects, advantages and features of the present invention will become
 apparent from a consideration of the following specification taken in
 conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
 In the illustrations given, and with reference first to FIG. 1, the
 reference numeral 10 designates generally a return envelope assembly for
 the payment of a bill with a personal check wherein the return envelope
 assembly 10 is prepared entirely from a one piece blank that includes a
 front panel 12 and a rear panel 14. The front and rear panels 12 and 14
 each have a top edge 12a and 14a, respectively, a bottom edge 12b and 14b,
 respectively, and a pair of side edges 12c, 12d and 14c, 14d, respectively
 with the front and rear panels being integral along their bottom edges 12b
 and 14b about a bottom fold line 16 such that the front panel 12 has an
 inner surface 12e which lies in confronting relation with an inner surface
 14e of the rear panel 14 after the envelope 10 is formed. Further, the
 return envelope assembly 10 includes side flaps 18 and 20 integral with
 the side edges 12c and 12d of the front panel 12 about respective side
 fold lines 22 and 24 about which the side flaps are folded inwardly to lie
 between the confronting inner surfaces 12e and 14e of the front and rear
 panels 12 and 14 (see FIGS. 2 and 3).
 With this construction, the return envelope also includes means such as a
 permanent adhesive as at 26 for securing each of the side flaps 18 and 20
 to the inner surface 14e of the rear panel 14 so as to be integral
 therewith. It still additionally includes means such as a moisture
 activated glue 28 on a closure flap 30 for sealing an opening defined by
 the top edges 12a and 14a of the front and rear panels 12 and 14.
 Moreover, the return envelope assembly 10 is such that the side flaps 18
 and 20 each have a minimum lateral spacing in relation to their opposite
 side edges 24 and 22 less than the width of a personal check (see
 dimension lines 32 and 34, respectively).
 In the embodiment illustrated in FIGS. 1-5, the front and rear panels 12
 and 14 are generally rectangular in shape and the closure flap 30 is
 integral with the top edge 12a of the front panel 12 in conventional
 fashion. It is advantageous for the side flaps 18 and 20 to each be formed
 such that they have generally parallel innermost edges 18a and 20a
 thereon. With this arrangement, the innermost edges 18a and 20a are
 separated from their opposite side edges 24 and 22 by the minimum lateral
 spacing that is less than the width of the personal check entirely
 therealong (see dimension lines 32 and 34).
 In a highly preferred embodiment, the minimum lateral spacing is on the
 order of at least approximately 1/4 inch, or at least approximately five
 percent, less than the width of a standard personal check of the type
 normally used for the payment of a bill.
 In another important respect, the return envelope assembly 10 incorporates
 what is conventionally known as a bangtail for removal from the envelope
 before the payment of a credit card bill with a personal check. The
 bangtail return envelope assembly simply incorporates a removable bangtail
 panel 36 wherein the bangtail panel 36 and rear panel 14 are integral
 along their top edges 14a and 36a about a second fold line 38. Still more
 specifically, the second fold line 38 preferably comprises a perforated
 line for separating the bangtail panel 36 from the envelope 10 prior to
 mailing a payment coupon, personal check and the bangtail panel in the
 envelope 10.
 In still other respects, the side flaps 18 and 20 each preferably have
 their free edges 18a and 20a positioned inwardly of the side edges 22 and
 24 of the front and rear panels 12 and 14. The innermost portions of the
 free edges 18a and 20a on the side flaps 18 and 20 also advantageously
 span a majority of the distance between the top and bottom edges 12a, 14a
 and 12b, 14b of the front and rear panels 12 and 14. Still additionally,
 the bangtail envelope assembly 10 is preferably formed so as to have an
 aspect ratio of between 1.3 and 2.5 and a minimum width of approximately
 five inches.
 Referring to FIG. 4, the bangtail panel 36, which may also be characterized
 as an extension panel, is shown folded over the rear panel 14 after the
 rear panel 14 has been folded over the side flaps 18 and 20. It is
 conventional in the credit card industry for the bangtail or extension
 panel 36 to have advertising, promotional, and/or order form information
 for products and the like. With this arrangement, the bangtail or
 extension panel 36 can be removed for use or removed and discarded prior
 to sealing the envelope 10 by using the adhesive 28 on the closure flap
 30.
 With reference now to FIG. 5, the unique aspect of the present invention is
 clearly illustrated by reason of the positioning of a personal check 40
 within the envelope 10 where it is shifted to have one of its side edges
 40a immediately adjacent the side edge 24. It will be seen that the
 opposite side edge 40b of the personal check 40 extends considerably
 beyond the innermost edge 18a of the side flap 18 in a direction toward
 the opposite side edge 22 of the envelope 10. Assuming the personal check
 40 has been properly placed between the front panel 12 and the side flaps
 18 and 20, there is no way for it to shift such that one of its side edges
 40a or 40b can become lodged between one of the side flaps 18 and 20 and
 the rear panel 14.
 As is well recognized in the field, personal checks are almost universally
 of a standard size, i.e., 6 inches in width. This makes it possible to
 utilize the benefits of the present invention by controlling the minimum
 lateral spacing from the innermost edges 18a and 20a of the side flaps 18
 and 20 to the opposite side edges 24 and 22 of the envelope 10 so as to
 ensure that a personal check such as 40 will not become lodged between one
 of the side flaps 18 and 20 and the rear panel 14 of the envelope 10.
 Moreover, other necessary or desirable inserts such as a payment coupon
 and a bangtail panel can also be dimensionally controlled.
 In other words, and specifically in relation to the credit card industry,
 the payment coupon and bangtail panel can be formed to have respective
 widths that are approximately equal to the standard width of a personal
 check. This serves to ensure that none of the contents of a return
 envelope assembly for the payment of a credit card bill will inadvertently
 become lodged between one of the side flaps and the rear panel of the
 return envelope assembly while in transit. On the contrary, due to the
 control of the minimum lateral spacing of the innermost edges of the side
 flaps in relation to the opposite side edges of the envelope, the contents
 of the return envelope assembly stay correctly positioned.
 Since the contents are correctly positioned, they properly enter the guide
 that is provided for them, rather than being captured in one of the guides
 for the front and rear panels of the envelope, after it has been slit by
 the automatic mail opening equipment so that, at a downstream location, a
 belt can properly grab the contents, i.e., the payment coupon, personal
 check, and bangtail panel, and automatically deliver them for processing.
 Due to the unique aspects of the present invention, it is now possible for
 the first time to avoid the frequent intermittent disruptions to operation
 of the automatic mail opening equipment thereby ensuring prompt processing
 of payments made to credit card companies at the earliest possible moment
 since there is no longer any realistic possibility that the contents of a
 return envelope assembly will become improperly lodged where they cannot
 be handled as intended.
 While in the foregoing there has been set forth a preferred embodiment of
 the invention, it will be appreciated that the details herein given may be
 varied by those skilled in the art without departing from the true spirit
 and scope of the appended claims.