Mailer with return envelope

Abstract: The C-fold mailer includes first, second and third panels (20,22,24) foldable about transversely extending foldlines to form a mailer with return envelope. Adhesive is applied to one face of the sheet along opposite side margins. The second and third panels (22,24) are folded and adhesively secured along three margins and the first panel (20) is adhesively secured along the outside face of the third panel. By arranging the lines of adhesive relative to perforated lines along the sides and one end of the mailer, registering sides and end portions of the mailer may be removed while retaining the return envelope adhesively secured along three sides. An integral flap is provided whereby a portion of the first panel may be used as a remittance slip. The slip may be inserted into the return envelope, and the flap folded to seal the return envelope.

Description: BACKGROUND OF THE INVENTION The present invention relates to a continuous business form web which can be separated into discrete forms and folded to form mailers having a return envelope, and particularly relates to a "C" fold mailer with return envelope which is relatively simple to produce and readily and easily knocked down or disassembled such that a portion of the mailer may be reused as a return envelope. The present invention also relates to a method of forming the C-fold mailer with return envelope. It is, of course, well known to use continuous business form webs which can be separated into discrete forms and folded to form mailers with integral return envelopes. Many of these mailers however, are difficult to produce on a continuous basis. For example in certain mailers, glue or adhesive is necessarily applied to both sides of the web, and this renders their production somewhat difficult and more expensive. Additionally, because of the multiple folds used in many mailers, printing is frequently necessary on both sides of the form. All of this increases the cost of producing the mailer. US Patent Specification US-A-4756468 describes a window style return mailer comprising two outer sheets with an inner sheet sandwiched between the two outer sheets and adhesively joined to one of the two outer sheets. Canadian Patent Specification No. CA-A-1168671 describes a foldable mailing form including longitudinal edge strips and a number of panels defined by fold lines about which the panels are folded to provide a mailer. Adhesive is applied to the edge strips of the panels. The adhesive area is detached by the recipient by tearing along perforation lines. US Patent Specification No. 3497132 describes various embodiments of two way mailing envelopes comprising a front panel joined to a back panel and a top flap to fold over the other panel and with a gum seal on each flap. Further, a number of mailers are confusing and difficult for the addressee to disassemble such that the return envelope is not torn or destroyed and remains intact and useful for its intended purpose. For example, many such mailers have multiple instructions at various locations about the mailer directed to the initial addressee. These instructions detail the sequence of steps necessary for the recipient of the mailer to open the mailer and retrieve its contents, such that at the same time, the return envelope may be retained in useful, intact condition. Still further, it has often been difficult in mailers to use preprinted information such that the slips or invoices included with the mailer may be disposed in the return envelope in a manner enabling the proper address to appear on the return envelope or even to fit within the return envelope. Many such invoices or the like must be folded by the original addressee in order to use the return envelope. SUMMARY OF THE INVENTION In acccordance with the present invention, there is provided a mailer with return envelope which is simple to produce, has all of the adhesive patterns applied to one side of the form, thereby facilitating its production at minimum cost, and permits most of the information, including variable information which may be computer-generated, to be applied to one side of the form, preferably the same side on which the adhesive is applied. The present invention also provides mailers in continuous sheet form whereby printing, adhesive application, and cutting and slitting operations on a high-speed basis may be accomplished. The cutting and slitting operations, of course, facilitate subsequent separation of the forms into individual mailers. Thus, the sheet form of the present invention is readily manipulated to form the mailer by automated processes. In a particular embodiment of the present invention, a continuous business form web is provided including a plurality of individual elongated sheets or forms attached one to the other by transversely extending lines of perforations whereby the individual sheets may be detached one from the other to form the mailers. Longitudinally extending lines of perforations are inset along and from the opposite edges of the sheets to define marginal feed strips. A plurality of longitudinally spaced tractor openings are provided along the marginal feed strips, whereby the continuous web may be fed automatically, for example, in a printer. Each sheet comprises first, second and third panels, longitudinally spaced one from the other. First and second foldlines are formed between the first and second panels and the second and third panels, respectively. On one side of the sheet, a heat seal adhesive is applied to the margins of the first panel outside of the longitudinally extending perforation lines and also transversely along the distal end of the first panel outwardly of a first laterally extending perforation line. This first perforation line is spaced longitudinally a predetermined distance from the distal end of the first panel. The first panel also has another transverse perforation line spaced from the first foldline and which defines between it and the first foldline a laterally extending strip on which vegetable-based ink is coated, for purposes which will become clear. These two lateral perforation lines in the first panel define a detachable panel portion or ticket which may, for example, comprise a remittance slip and associated stub or receipt. The second panel is preferably free of adhesive and has a die-cut window through which recorded information, for example, an address, may be displayed. The second panel also has a second laterally extending perforation line spaced longitudinally a predetermined distance from the second foldline, ie the same distance the first perforation line in the first panel is spaced from the distal end of the first panel. The third panel has a third laterally extending perforation line spaced from the second foldline a distance equal to the distance the transverse perforation line in the second panel is spaced from the second foldline. Additionally, the side margins of the third panel, as well as the laterally extending margin of the third panel adjacent the second foldline are provided with a heat-seal adhesive. More particularly, the side adhesive margins in the third panel straddle the longitudinaly extending perforation lines. Similarly, the adhesive applied adjacent the second foldline also straddles the third laterally extending perforation line of the third panel. On the distal end of the third panel, there is provided a flap foldable about a third laterally extending foldline. A rewettable adhesive is applied to the flap. To fold the sheet to form the mailer, a C-type folding is provided. Particularly, the second and third panels are folded about the second foldline such that the adhesive applied to the third panel registers with the face of the second panel. This locates the flap with its rewettable adhesive in opposition to the laterally extending strip of the first panel coated with the vegetable-based ink whereby adherence of the rewettable adhesive to the first panel is prevented. The first panel, together with the flap, may then be folded over the back side of the third panel such that the adhesive about the margins of the first panel registers with the margins of the third panel. By applying heat, the adhesive is activated to secure the panels together and form the mailer. By folding the sheet in this manner, the longitudinal extending perforation lines in each panel register each with the other, while the first, second and third laterally extending perforation lines of the first, second and third panels, respectively, register each with the other. Additionally, address information is provided on the face of the third panel which, when folded to form the mailer, appears for display through the die-cut window of the second panel. When the mailer is received, the recipient tears the opposite side marginal portions along the longitudinally registering perforation lines to remove them. The recipient also tears along the top of the mailer along the first, second and third laterally extending and registering perforation lines. It will be appreciated that, because the adhesive on the third panel straddles the longitudinal and transversely extending perforation lines, the removal of the side and top margins of the mailer enables the adhesive inset from those longitudinally registering perforation lines and the adhesive inset from the second and third laterally registering perforation lines to maintain the three sides of the second and third panels secured one to the other to define the return envelope and maintain it intact. After the side margins and top of the mailer are removed, it will be appreciated that the first panel is free, except for its attachment via the first foldline to the second panel. Preferably, that foldline is perforated, enabling the first panel to be removed entirely from the return envelope formed by the second and third panels. Once removed, the remaining strip of the first panel bearing the vegetable-based ink coating can be removed leaving the panel portion or ticket. The ticket normally comprises a stub or receipt and a remittance slip. After the stub and remittance slip are separated, the remittance slip can be disposed in the return envelope without folding with the return address on the opposite face of the remittance slip appearing through the window of the second panel. The flap on the end of the third panel may then be wetted to activate the rewettable adhesive and folded over onto the outside face of the second panel to seal the return envelope with the remittance slip inside. Consequently, it will be appreciated that both the heat seal and rewettable adhesive are applied to one face of the sheet and substantially all of the printing, except for the return address on the remittance slip, is likewise applied to that same face. In another form of the present invention, the flap for the return envelope is formed within the confines of the third panel rather than constituting an extension of the third panel at its distal end. Also, instead of coating a portion of the first panel with a lateral strip of vegetable-based ink, a lateral strip of the second portion adjacent the first foldline is coated with the ink such that, upon folding the second and third panels about the second foldline, the rewettable adhesive of the flap of the third panel lies in opposition to the vegetable-based ink coating on the second panel. This embodiment requires an additional tearing of the coated strip along another perforation line in the second panel such that the flap of the third panel can be folded about a third foldline for adhesive securement to the opposite face of the second panel. Accordingly, it is a primary object of the present invention to provide a novel and improved C-fold mailer with integral return envelope and remittance slip, which is readily and easily manufactured in a single, continuous business form web, relatively easily opened and disassembled to form the return envelope and remittance slip, and readily reused for return mailing with the remittance slip disposed in the return envelope and to a method of making the C-fold mailer. These and further objects and advantages of the present invention will become more apparent upon reference to the following specification, appended claims and drawings. BRIEF DESCRIPTION OF THE DRAWING FIGURES Figure 1 is a fragmentary plan view of a continuous business form for forming mailers constructed in accordance with the present invention; Figure 2 is a view similar to Figure 1 illustrating the reverse side of the form illustrated in Figure 1; Figure 3 is a front elevational view of the mailer illustrating the address side of the mailer; Figure 4 is a view similar to Figure 3 illustrating the reverse side of the mailer; Figure 5 is a side elevational view of the mailer after opening with a first panel thereof defining a remittance slip and stub removed from the second and third panels forming the return envelope; Figure 6 is a perspective view of the reverse side of the return envelope illustrated in Figure 5 with the remittance slip poised for placement within the return envelope; Figure 7 is a view on a reduced scale of another embodiment of a mailer according to the present invention; Figure 8 is a perspective view of the return envelope and remittance slip and stub of the embodiment thereof illustrated in Figure 7; Figure 9 is a view similar to Figure 8 illustrating the insertion of the remittance slip into the return envelope; Figure 10 is a perspective view illustrating the C-fold of the mailer of the first embodiment hereof; and Figure 11 is a perspective view similar to Figure 10 illustrating the C-fold of the mailer of the second embodiment hereof. DETAILED DESCRIPTION OF THE DRAWING FIGURES Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Referring now to Figure 1, there is illustrated a continuous business form web, generally designated 10, comprised of a single ply of paper separable into elongated sheets for forming discrete mailers 12, respectively. The sheets in the continuous form web 10 are joined one to the other at opposite ends by laterally extending lines of perforations 14. It will be appreciated that the continuous business form web 10 has a plurality of tractor openings 16 spaced longitudinally one from the other along opposite sides of the form such that the continuous form can be handled by machines having correspondingly spaced tractor pins, such as high-speed printers, not shown. In this manner, the single continuous ply of paper may be disposed in various machines common in the printing industry for performing slitting, printing and adhesive applying operations on various portions of the form, as described hereinafter. As will be seen from a review of Figures 1, 2 and 10, each elongated sheet, when separated from the continuous form 10 along the transverse lines of perforations 14, may be formed into a mailer 12. Each mailer 12 is comprised of first, second and third panels 20, 22 and 24, respectively, longitudinally spaced one from the other along the sheet. First and second panels 20 and 22, respectively, are joined one to the other along a transversely extending foldline 26, while second and third panels 22 and 24 are similarly joined one to the other along a transversely extending foldline 28. The foldlines comprise weakened portions of the paper and may be formed by providing lines of perforations for purposes of either ultimately separating the panels one from the other or for weakening the paper to enable folding where ultimate separation is not required or desired. Thus, the term "foldline" as used herein means a weakened portion of the paper for purposes of folding the paper and does not necessarily include or exclude lines of perforations for purposes of separating one panel from the other. From a review of Figures 1, 2 and 10, it will also be appreciated that the continuous business form web 10 includes straight lines of perforations 30 and 32 extending longitudinally along the respective opposite sides of the form the entire length thereof inset from the tractor openings 16. The marginal strips 34 and 36, defined by the lines of perforations 30 and 32, respectively, enable the continuous form web to proceed through the manufacturing process, including the slitting, printing and gluing operations, and form an integral part of the mailer, as will be appreciated from the ensuing description. From an inspection of Figures 1 and 2, it will be seen that the first panel 20 also includes a transverse line of perforations 38 which extends transversely between the longitudinally extending lines of perforations 30 and 32. Perforation line 38 is spaced longitudinally a predetermined distance from separation line 14 of the first panel 20. Additionally, and with reference to Figures 1 and 2, the first panel 20 includes a transverse line of perforations 40 extending between the longitudinally extending perforation lines 30 and 32 and spaced from foldline 26. Transverse perforation lines 38 and 40, together with the longitudinally extending perforation lines 30 and 32, define the margins of a ticket 46. The ticket 46, as best illustrated in Figure 2, is comprised of a major portion 48 which, for example, may be a remittance slip and a minor portion 50, which may, for example, form a stub. The remittance and stub portions of the ticket 46 are separable one from the other by a perforation line 52, which extends longitudinally between the transverse perforation lines 38 and 40 adjacent one side of ticket 46. Panel 22 likewise has a transversely extending line of perforations 54 extending between the longitudinally extending perforation lines 30 and 32 and spaced longitudinally from the foldline 28 a distance equal to the distance perforation line 38 is spaced from the separation line 14 of panel 20 and a distance less than the distance between the second perforation line 54 and the first foldline 26 and defining an end margin adjacent the second foldline. Panel 22 also includes a die-cut window 56 opening through mailer 12. Third panel 24 includes a transverse perforation line 58 extending between the longitudinal perforation lines 30 and 32 and spaced longitudinally from transverse foldline 28 a distance equal to the distance the perforation line 54 extends longitudinally from foldline 28 and defining another end margin adjacent the second foldline for reasons which will become apparent from the ensuing description. Also referring to Figures 1, 2 and 10, a foldline 60, for example, comprised of transversely extending perforations, is spaced longitudinally from the separation line of perforations 14 in panel 24 to define a flap 62 for purposes which will become clear. Rewettable glue or adhesive 63 is provided along the inside face of flap 62. The third panel 24 has, on the face thereof illustrated in Figure 2, pre-printed information which may be variable and computer-generated, for example, an outgoing address, which, when the sheet 12 is folded to form the mailer, will appear through the window 56. Additionally, the remittance portion 48 of the ticket 46 includes a return address as illustrated in Figure 1 which, when inserted in the return envelope, will similarly appear through the address window 52. For reasons described hereinafter, a transversely extending strip of vegetable-based ink 55 is provided transversely along the inner margin of first panel 20 between perforation line 40 and foldline 26. It will be appreciated that, in this embodiment, panels 20 and 22 extend longitudinally a like distance, whereas panel 24 extends longitudinally from foldline 28 to foldline 60 a like longitudinal distance but additionally carries a further longitudinal portion constituting flap 62. Referring now to Figures 2 and 10, the reverse side of the mailer from the side illustrated in Figure 1 is provided with strips of adhesive at predetermined locations along the panels such that the mailer 12 can be assembled and subsequently knocked down to form a return envelope. Turning now particularly to Figure 2, the opposite sides of the first panel 20 has a permanent type heat sealable adhesive applied to the lateral margins at 64 and transversley along the distal end margin at 66. The adhesive strips 64 along the lateral margins straddle the tractor openings 16 and are spaced laterally outwardly of the longitudinally extending lines of perforation 30 and 32, respectively. The distal end adhesive strip 66 is also spaced outwardly of the transverse perforation line 38. Consequently, ticket 46, defined by the longitudinally extending perforation lines 30 and 32 and the transversely extending perforation lines 38 and 40, is wholly free of adhesive. As illustrated in Figure 2, the second or intermediate panel 22 is also preferably wholly free of adhesive. The third panel 24 similarly has a permanent type heat sealable adhesive applied to marginal portions. For example, the lateral margins of the third panel are provided with adhesive strips 68 inset from tractor openings 16 and which strips 68 straddle the longitudinally extending lines of perforation 30 and 32, respectively, in the third panel. A transversely extending strip of permanent type heat sealable adhesive 70 is also applied to third panel 24 and has a width which extends from the foldline 28 longitudinally beyond the line of perforations 58 such that the perforation line 58 is straddled by adhesive margin 70. It will be appreciated from Figure 2 that the longitudinally extending adhesive strips 68 terminate at the foldline 60 which defines flap 62. As indicated previously, flap 62 is provided with a rewettable adhesive strip 63 which extends transversely at least the length of flap 62 between perforation lines 30 and 32. It will be appreciated from the following description of the assemblage of the mailer that one or other or both of the marginal adhesive strips 68 and 70 could be located along the second panel rather than along the third panel in corresponding positions when the panels are folded to form the rerturn envelope as described hereinafter. To assemble the mailer, reference is made to Figure 10. In Figure 10, the panels 20, 22 and 24 are folded into a generally C-shaped configuration about foldlines 26 and 28. The first panel is folded about the first foldline to register the first panel and the third panel on face to face opposition one to the other and to adhesively secure the lateral and distal end margins of the first panel to the lateral end margins of the third panel. More particularly, flap 62 is folded about foldline 60 and panels 22 and 24 are folded in the opposite direction about foldline 28 such that the adhesive margins 68 and 70 on panel 24 register the second and third panel faces in opposition one to the other and to adhesively secure and register (a) the lateral margins of the second 22 and third 24 panels one to the other and (b) the end margins adjacent the second foldline of the second and third panels one to the other Thus, the out-going address information on the inside face of panel 24 appears in the window 56. After the second and third panels 22 and 24 have been folded together, the first panel 20 is folded about foldline 26 to overlie flap 62, particularly on the rewettable adhesive side 63 of flap 62, the first panel 20 extending along the outside face of panel 24. Heat is applied to the mailer along the margins such that the heat-sealable adhesive is activated and secures the panels one to the other to form the mailer. When the mailer is completely folded, it will be apreciated that the longitudinal lines of perforation 30 and 32 in each of the panels lie in registry each with the other. Also, when the panels are completely folded as indicated, the transverse perforation lines 38, 54 and 58 register one with the other. In particular the lateral and distal end margins of the front panel are registered with the lateral and distal end margins of the third panel to form a mailer such that the first 38, second 54 and third 58 straight lines of perforations are in registration each with the other and the longitudinally extending lines 30, 32 of perforations lie in registration each with the other whereby the lateral margins defined by registering straight lines of perforations 30, 32 extending longitudinally along the first, second and third panels and one end margin of the mailer defined by the registering first, second and third straight line of perforations may be removed along the registering lines of perforations to form a return envelope defined by the second 22 and third 24 panels. Further, the rewettable adhesive 63 along flap 62 registers with the vegetable-based ink 55 formed on the first panel 20 such that the rewettable adhesive 63 is prevented from adhering to the first panel when the mailer is folded and heat is applied. As a result of the heat-sealing, it will be appreciated that the first panel 20 is secured to the outer face of the second panel 22 by the marginal adhesive strips 64 and 66 outwardly of the longitudinally registering perforation lines 30 and 32 and the transversely registering perforation lines 38, 54 and 58, respectively. It will also be appreciated that the marginal adhesive strips 68 and 70 secure the second and third panels one to the other in a manner such that strips 68 straddle the registering perforation lines 30 and 32 and strip 70 straddles the registering perforation lines 54 and 58. In this manner, when the recipient receives the mailer, the three plies of lateral marginal strips 34 and 36 registering one with the other may be removed from the mailer by tearing along the aligned perforation lines 30 and 32. The transverse marginal strips of the first, second and third panels may likewise be removed by tearing along the registered transversely extending perforation lines 38, 54 and 58. That is, by tearing along those latter perforation lines, the strip of the first panel 20 between perforation line 38 and the first panel separation line 14, the strip in second panel 22 between perforation line 54 and foldline 28, and the strip in the third panel 24 between perforation line 58 and foldline 28 may be simultaneously removed. It will be apprecated that by removing these longitudinal and transverse strips, the second and third panels remain adhered one to the other along three of their four margins to define the return envelope. That is, the portions of the adhesive on the third panel 24 inset from the perforation lines 30, 32 and 58 remain and secure the second and third panels one to the other. However, an opening for the return envelope is defined between the distal end of the third panel and the margin of the second panel adjacent the First Foldline 26. When the second and third panels are secured together the opening provides a mouth for receipt of an insert. First panel 20, of course, remains secured to the return envelope at foldline 26. Having removed the marginal and transverse strips, the recipient of the mailer may then remove first panel 20 by tearing along foldline 26. The ticket 46 is then separated from first panel 20 by tearing along perforation line 40. Stub 50 may then be removed from the resulting ticket 46 such that only the remittance slip 48 remains. The remittance slip is now of a size for disposition in the return envelope. Information on the remittance slip may then be completed by the recipient of the mailer as necessary and additional materials, for example a check, may be disposed in the return envelope with the remittance slip. The remittance slip is, of course, located such that the return address appears through window 56. The flap 62 is then wetted and folded about foldline 60 to seal the return envelope. Referring now to the embodiment hereof illustrated in Figures 7 and 11, wherein like reference numerals refer to like parts, followed by the suffix a, there is illustrated a mailer 12a, wherein the panels 20a, 22a and 24a are of like longitudinal extent. The panel 20a is identical to the panel 20 in the previous embodiment, except that the vegetable-based ink is not provided in the transverse strip between the perforation line 40a and foldline 26a. The adhesive strips and perforations are otherwise identical. The intermediate or second panel 22a is similarly identical to the panel 22 illustrated in the previous embodiment, except that a perforation line 70 extends transversely between the longitudinally extending lines of perforation 30a and 32a adjacent the foldline 26a to provide a detachable strip 72. The vegetable-based ink 55a is applied to the detachable strip 72 on the adhesive side of the mailer. As described hereinafter, strip 72 is detachable from the mailer after the recipient receives the mailer and prior to using the return envelope. The third panel 24a is identical to the third panel 24 of the previous embodiment, with the exception that its longitudinal extent is the same as the longitudinal extent of each of panels 20a and 22a. Rewettable glue 63a is applied to the flap 62a defined between the separation line 14a of the third panel and the perforation line 60a. As in the previous embodiment, the adhesive strips 68a along the lateral margins of the third panel and 70a along the margin thereof adjacent foldline 28a straddle the perforation lines 30a, 32a and 58a. In this form, the second and third panels 22a and 24a are folded about foldline 28a such that the perforation lines 30a and 32a in the second and third panels 22a and 24a, respectively, register one with the other and such that perforation lines 54a and 58a register one with the other. The first panel 20a is then folded about foldline 26a to overlie the outer face of the third panel 24a, with its longitudinally extending perforation lines 30a and 32a in registry with perforation lines 30a and 32a of the second and third panels 22a and 24a, respectively. Likewise, the perforation line 38a registers with the perforation lines 54a and 58a of the second and third panels, respectively. Thus, when the adhesive is activated by application of heat, the second and third panels are secured one to the other along three of their four margins, while the first panel is secured to the outer face of the third panel along the side margins and lower edge of the first panel. When the recipient receives the mailer, the marginal strips may be removed by tearing along the aligned perforation lines 30a and 32a. Also, removed by tearing along the registering perforation lines 38a, 54a and 58a are the adjoining strips of the second and third panels and the distal strip of the first panel. Consequently, the return envelope is comprised of the second and third panels 22a and 24a, joined by the adhesive inset from perforation lines 30a, 32a and 58a along the side and bottom margins, respectively, with the opening to the return envelope being provided between the free edge of flap 62a and foldine 26a. The recipient then removes the ticket 46a by tearing along the perforation lines 40a or 70 or along foldline 26a. The remittance slip is then separated from the stub and the remittance slip, together with additional materials as necessary, i.e., is placed in the return envelope with its return address displayed through window 56a. If the strip 72 has not previously been removed, it may then be removed by tearing along perforation line 70, enabling the flap 62a with the rewettable glue to be folded about perforation line 60a onto the reverse side of the second panel to seal the return envelope. It will be appreciated that the objects of the present invention are fully accomplished in the foregoing construction in that the glue, both the heat-sealable and rewettable glue, are applied to but one face of the continuous form. The vegetable-based ink is likewise applied to the same side of the form. Additionally, most of the printing may be applied to one side of the form. All of the printing may be performed on one side of the form if the return address on the remittance slip is disposed on its reverse side than as shown. Further, very little paper is wasted inasmuch as the marginal strips with the feed holes form part of the mailer forwarded to the recipient.

Claims: A mailer with integral return envelope comprising: an elongated sheet (10) having first (20) second (22) and third (24) panels longitudinally spaced one from the other along the sheet (10) and connected one to the other along first (26) and second (28) laterally extending, longitudinally spaced, fold lines, respectively; on one face of the sheet (10), adhesive (66) applied to the lateral margins (64) of the first panel (20), the lateral margins (68) of one of the second (22) and third (24) panels, the distal end margin (66) of the first panel, and an end margin (70) of one of the second (22) and third (24) panels immediately adjacent the second foldline (28); straight lines of perforations (30, 32) extending longitudinally along the entire length of the sheet along opposite sides thereof, the adhesive (64) on the respective lateral margins of the first panel (20) face being disposed laterally outwardly of the longitudinally extending lines of perforations (30, 32) in the first panel (20) and the adhesive (68) on the lateral margins of the one of the second (22) and third (24) panels straddling the longitudinally extending lines of perforations (30, 32) in the corresponding panel; the second panel (22) having a window (56) formed therein such that address information on the face of the third panel (24) may be displayed through the window (56) when the panels are folded to form the mailer, and means carried by the first panel (20) including at least one line of perforations (52) defining a portion (50) of the first panel removable from the first panel and receivable in the return envelope without folding; characterised in that first (38), second (54) and third (58) straight lines of perforations extend laterally respectively in the first (20) second (22) and third (24) panels, the first perforation line (38) being inset from the distal end margin of adhesive (66) in the first panel, the second perforation line (54) extending in the second panel (22) adjacent to and spaced longitudinally from the second foldline (28) a distance less than the distance between the second perforation line and the first foldline and defining an end margin adjacent the second foldline, the third perforation line (58) in the third panel (24) being spaced longitudinally from the second foldline (28) substantially the same distance that the second perforation line (54) in the second panel (22) is spaced from the second foldline (28) and defining another end margin adjacent the second foldline, the end margin of adhesive on the one of the second (22) and the third (24) panels straddling one of the second (54) and third (58) laterally extending lines of perforations therein; and in that the second (22) and third (24) panels are relatively foldable about the second foldline (28) to register the second (22) and third (24) panel faces in opposition one to the other and to adhesively secure and register (a) the lateral margins of the second (22) and third (24) panels one to the other and (b) the end margins adjacent the second foldline of the second and third panels one to the other, and the first panel being foldable about the first foldline to register the first panel and the third panel in face to face opposition one to the other and to adhesively secure the lateral and distal end margins of the first panel to the lateral end margins of the third panel to form a mailer and such that the first (38), second (54) and third (58) straight lines of the perforations lie in registration each with the other whereby the lateral margins defined by registering straight lines of perforations (30, 32) extending longitudinally along the first (20), second (22) and third (24) panels and one end margin of the mailer defined by the registering first, second and third (38, 54, 58) straight lines of perforations to form a return envelope defined by the second (22) and third (24) panels. The mailer according to Claim 1 wherein the return envelope has an opening defined between the distal end of the third panel (24) and the margin of the second panel (22) adjacent the first foldline (26) when the second (22) and third (24) panels are secured one to the other to provide a mouth for receipt of an insert. The mailer acccording to Claim 1 or 2 wherein the first panel (20) has return address information thereon and is receivable in the return envelope to display the address information through the window (56). The mailer according to any one of Claims 1, 2 or 3 wherein the sheet (10) has a laterally extending flap (62) adjacent the distal end of the third panel (24), a third foldline (60) between the flap (62) and the third panel (24), the flap having a rewettable adhesive (63) applied to the same side of the the sheet as the marginal adhesives, the first panel (20) being removable from the mailer along the first foldline (26), the flap (62) being foldable about the third foldline (60) in one direction to lie in opposition to the first panel (20) when the first, second and third panels are folded to form the mailer and in the opposite direction, after the first panel (20) has been removed, to close the return envelope with the rewettable adhesive (63) on the flap (62) securing the flap to the opposite face of the second panel. The mailer according to Claim 4 wherein a laterally extending margin of the first panel (20) adjacent the first foldline (26) and in opposition to the adhesive (63) on the flap (62), when the panels (20, 22, 24) are folded to form the mailer, has a coating (55) for substantially preventing adhesion of the flap (62) to the first panel (20). The mailer according to Claim 5 wherein the coating (55) is comprised of a vegetable-based ink. The mailer according to any one of the preceding claims wherein the sheet (10) forms part of a continuous business form web, the lateral margins (34, 36) of the sheet having a plurality of longitudinally spaced tractor openings (16) for receiving tractor pins. The mailer according to any one of the preceding claims wherein the longitudinal extent of each of the first (20) and second panels (22) is substantially identical one to the other. The mailer according to any one of the preceding claims wherein the adhesive is applied solely to one face of the sheet and the second panel face is free of any adhesive. A method of forming a mailer with an integral return envelope comprising the steps of; providing an elongated sheet (10) having first (20), second (22) and third (24) panels longitudinally spaced one from the other along the sheet and connected one to the other along first (26) and second (28) laterally extending longitudinally spaced foldlines, respectively; providing straight lines of perforations (30, 32) extending longitudinally along the entire length of the sheet along opposite sides thereof; and forming a window in the second panel such that address information on the face of the third panel may be displayed through the window when the panels are folded and adhesively secured to form the mailer. characterised in that there is provided first (38), second (54) and third (58) transversely extending straight lines of perforations, respectively, in the first (20), second (22) and third (24) panels, the first perforation line (38) being inset from the distal end of the first panel, the second perforation line (54) extending in the second panel adjacent to and spaced longitudinally from the second foldline (28), the third perforation line (58) in the third panel being spaced longitudinally from the second foldline (28) substantially the same distance that the second perforation line (54) in the second panel is spaced from the second foldline (28); and in that adhesive is applied solely to one face of the sheet (10), particularly along the lateral margins of the first panel (20) outwardly of the longitudinally extending lines of perforations (30, 32) in the first panel (20), the lateral margins of one of the second (22) and third (24) panels such that the adhesive margin (68) straddles the longitudinally extending lines of perforations (30, 32) in the one of the second (22) and third (24) panels, the distal end margin of the first panel (20) outwardly of the transversely extending line of perforations (38) of the first panel and an end margin of one of the second (22) and third (24) panels immediately adjacent the second foldline (28) such that the adhesive margin straddles the transversely extending line of perforations in the one of the second (22) and third (24) panels; and in that the second (22) and third (24) panels are folded relative to one another about the second foldline (28) to register the second (22) and third (24) panel faces in opposition one to the other and adhesively securing the registering margins of the second (22) and third (24) panels one to the other along the adhesive margin; and in that the first panel (20) is folded about the first foldline (26) and the adhesive margins of the first panel (20) are adhesively secured to the opposite face of the third panel to form a mailer; whereon the steps of folding and adhesively securing being such that the first, second and third lines of perforations lie in registration each with the other and the longitudinally extending lines of perforations lie in registration each with the other whereby the lateral margins and one end margin of the mailer form a return envelope defined by the second and third panels. The method according to Claim 10 including the step of forming an opening between the distal end of the third panel (24) and the margin of the second panel (22) adjacent the first foldline (26) when the second (22) and third (24) panels are folded and secured one to the other to provide a mouth for receipt of an insert. A method according to Claim 10 or 11 including the steps of forming a laterally extending flap (62) adjacent the distal end of the third panel (24) and foldable about a third foldline (60) between the flap (62) and the third panel (24) and applying rewettable adhesive (63) to the flap (62) and to the same side of the sheet as the marginal adhesives. The method according to Claim 12 including the step of applying a coating (55) along a laterally extending margin of the first panel (20) adjcent the first foldline (26) and in opposition to the adhesive (63) on the flap (62), when the panels (20, 22, 24) are folded to form the mailer, for substantially preventing adhesion of the flap (62) to the first panel (20). The method according to Claim 12 including the steps of providing another laterally extending line of perforations (70) along the second panel (22a) adjacent to, but spaced from, the first foldline (26a) to define a strip (72) removable from the second panel, and applying a coating to the detachable strip for substantially preventing adhesion of the flap (62a) to the second panel when the panels are secured one to the other to form the mailer.

Inventors: TAYLOR JIM C, TAYLOR, JIM C.
Applicants: MOORE BUSINESS FORMS INC, MOORE BUSINESS FORMS, INC.
Application year: 1989
Main classification: B42D5
IPC codes: B42D5, B42D15