Mailers and business form assemblies for producing mailers

Abstract: The invention relates to a sealed mailer or a business form assembly for providing a series of such mailers. In one form, the mailer has a folded edge and three other edges sealed by adhesive. A line of perforation extends along a first edge opposite the folded edge. Adhesive along the other two opposite edges is of a peel-apart arrangement such that after the first edge has been detached, the other two edges can be peeled apart to open out the mailer without significantly damaging the mailer. In another form, two rectangular sheets are sealed along all four edges with a line of perforation along a marginal edge portion of a first of the edges. Two edges adjacent the first edge and extending normal thereto are secured to one another by a peel-apart adhesive arrangement such that after the first edge portion has been torn off along the line of perforation, the two sheets from which the mailer is formed can be peeled apart from one another without significantly damaging the mailer.

Description: This invention relates to mailers and business form assemblies for producing such mailers. The invention is particularly applicable to business form assemblies comprising a substantially continuous web containing a plurality of mailer forming units separable from one another by first transverse lines of perforation extending completely across the web, each mailer forming unit comprising a front sheet and a back sheet of similar size, the mailer forming unit carrying non-active, but activatable, adhesive such that a sealed mailer unit can be formed by folding the unit to bring the front and back sheets in register and activating the adhesive to form a seal along the three non-folded edges. Most conventional mailers have the three sealed edges detachable along perforation lines which extend inside the lines of adhesive so that after the marginal edge portions have been removed by tearing along the lines of perforation the mailer can be opened out along the fold line. EP-A-0365162 relates to a business form assembly comprising separate webs adapted to be sealed together to form a sealed mailer with two opposite edges sealed by a continuous line of adhesive and two other opposite edges sealed by non-continuous lines of adhesive. All the adhesive for the edge sealing is initially on a cover one of the webs with no adhesive on the other web. AU-D-47023/68 describes a two-ply business form assembly providing individual sealed mailers, comprising a top web and a bottom web, the bottom web carrying credit cards adhered thereto and the top web formed with windows aligned with but smaller than the credit cards. The webs are secured together around the edges of each mailer by a mixture of continuous and non-continuous lines of adhesive. All the adhesive is initially on one of the webs with none on the other web. US-A-4148430 describes a business form assembly for providing sealed mailers, the assembly being formed from an outer sheet which is folded along a central longitudinal line. One half of the outer sheet carries all the adhesive for sealing the edges of the eventual sealed mailer. The present invention provides a business form assembly comprising a plurality of mailer units, each unit comprising a web having a central fold line such that the unit can be folded over along said central fold line to form a mailer having a front sheet and a back sheet overlying one another with the edges of the front and back sheets in register with one another, the front and back sheets having edge portions perpendicular to said fold line and edge portions parallel to the fold line, at least parts of an edge portion parallel to the fold line carrying a first non-active adhesive such that, when said edges of said parallel edge portions are brought together, a first substantially continuous line of adhesive is provided for sealing said parallel edge portions together; detachment lines of perforations extending along said parallel edge portions inside said first adhesive line, parts of said perpendicular edge portions having non-active, non-continuous second lines of adhesive therealong, such that when the unit is folded to bring said perpendicular edge portions together second peel-apart lines of non-continuous adhesive are provided for sealing these edges together along their length in a manner enabling the edges thereof to be peeled apart, characterised in that a part of each parallel edge portion carries adhesive and a part of each parallel edge portion is void of adhesive such that when said parallel edge portions are brought together the adhesive parts on one edge register with the void parts on another edge to provide the substantially continuous first line of adhesive, and each of the sheets (23, 24) having along at least one of its perpendicular edge portions has non-continuous second line of adhesive comprising discrete areas of adhesive separated by areas void of adhesive, arranged such that when the edges of the perpendicular edge portions are brought together the discrete areas of adhesive on one sheet register with void areas on another sheet to provide the non-continuous second lines of adhesive, the spacing between said spaced apart discreet areas of adhesive of the non-continuous lines being such that when the perpendicular portions (33, 34) are brought together the total area free of adhesive along each non-continuous adhesive line is at least twice the total area covered by such adhesive. The invention extends to a sealed mailer formed from such an assembly. The spacing of discrete areas of adhesive is such that the area free of adhesive along the line of peel-apart adhesive is preferably three to six times as great and with advantage about four to five times as great as the area covered by adhesive. The central fold line of the mailer may extend transversely or longitudinally of the web, depending upon the desired dimensions. The adhesive in this embodiment is arranged substantially symmetrically of the units so that each half of the unit carries substantially half the adhesive. Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWING FIGURES Figure 1 illustrates a first embodiment of mailer forming unit forming part of a business form assembly according to the present invention; Figure 2 illustrates the web of Figure 1 on a reduced scale; Figure 3 illustrates a mailer formed from the unit of Figure 1, on a reduced scale and at a later stage of the processing; Figure 4 is similar to Figure 1 showing a further form of the embodiment of Figure 1; Figure 5 illustrates a later processing stage of the mailer units of Figure 4. DETAILED DESCRIPTION OF THE DRAWING FIGURES Referring now to Figures 1 to 3, a mailer forming unit 12 has longitudinally extending edges 13, 14 and upper and lower transverse edges 15, 16. The unit 12 forms part of a continuous web 17 having a plurality of such units, with each unit separable from adjacent units by transverse lines of perforation 20. As particularly seen in Figure 2, the lines of perforation 20, when broken, form the upper and lower of the transverse edges of the mailer. The lateral edges of the web are formed with sprocket guide holes 19 in a known manner. Each mailer forming unit has an inside face 21, an outside face 22, a front sheet 23 and a back sheet 24, the front and back sheets being separated from one another by a central fold line 26. Fold line 26 is also preferably perforated or scored as shown. The front sheet is formed, in a known manner, with a window 27 so that when the unit is folded, an address 28 will be viewable through the window. Part of the edge portions 30, 31 of the edges parallel to the fold line 26 and which will form the opposite edge of the mailer to the fold line, carry non-active, but heat activatable, adhesive 32. Each of the edge portions 30, 31 carries a line of adhesive extending continuously a distance equal to about half the length of the edge portion and is void of adhesive for the other substantially one half thereof. When the edges are brought together, adhesive 32 will form a substantially continuous line of adhesive securing those edges one to the other. The edge portions 33, 34 extending normal to the fold line carry spaced-apart spots of non-active, but heat activatable, adhesive 35. When the unit is folded, adhesive 35 will provide a line of peel-apart adhesive along both such edges. In a preferred form, each spot 36 of adhesive 35 is square or diamond-shaped, with each side having a length of 0.2 cms and the spots spaced apart by about 0.7 to 0.95 cms. It should be noted that approximately half of the adhesive is on the upper sheet and half on the lower sheet to provide a substantially even weighted and balanced unit. The adhesive may be activatable by other means. Lines of perforations 37, 38 are formed adjacent the edge portions 31, 32 parallel to the central fold line 26 and inside the adhesive line 32. The web may have pre-printed information thereon and information is common to all forms. The business who wishes to send out the mailers will then pass the web through a printer to provide indivualized information on each form, such as the addresses 28. The longitudinal edges carrying the perforations 19 are then detached and the individual units burst from one another along the perforation lines 20. The units are then folded as seen in Figure 3 and passed through a sealer unit in which the adhesive is activated to form the sealed edges. To open the unit, for example, when received through the mail, the edge opposite the fold line is torn off along the registering perforation lines 37, 38. The front and back sheets are then peeled apart from each other along edge portions 33, 34 to open out the mailer. The form of business form assembly of Figures 4 and 5 is substantially similar and like parts have been given like reference numerals and will not be re-described. In this form, the transverse fold line of Figures 1 to 3 has been replaced by a longitudinally extending fold line 26a and the tear-off edge extends longitudinally instead of transversely of the web. The edge portions 33, 34 carrying the heat activatable adhesive in a peel-apart arrangement, as previously described, have relatively widely spaced peel-apart spots of adhesive, with the spots on the top sheet and the bottom sheet, respectively, spaced at different distances from the fold line 26a so that they will be interspaced when the edges are brought together. A substantially continuous fold line could also be formed by interspaced patches of adhesive, some on the top and some on the bottom sheet, and the peel-apart spots could also be interspaced in the mailer of Figures 1 to 3. As illustrated in Figure 5, the web is folded about the central longitudinal fold line 26a. The sprocket holes may then be detached and the web passed through a sealer unit to activate the glue and seal the edges. The units may then be detached from one another in a burster to provide the finished mailers.

Claims: A business form assembly (12) comprising a plurality of mailer units, each unit comprising a web having a central fold line (26) such that the unit can be folded over along said central fold line to form a mailer having a front sheet (23) and a back sheet (24) overlying one another with the edges of the front and back sheets in register with one another, the front and back sheets having edge portions (33, 34) perpendicular to said fold line and edge portions (30, 31) parallel to the fold line, at least parts of an edge portion (30, 31) parallel to the fold line carrying a first non-active adhesive (32) such that, when said edges of said parallel edge portions (30, 31) are brought together, a first substantially continuous line of adhesive is provided for sealing said parallel edge portions together; detachment lines of perforations (37, 38) extending along said parallel edge portions (30, 31) inside said first adhesive line, parts of said perpendicular edge portions (33, 34) having non-active, non-continuous second lines of adhesive (35) therealong, such that when the unit is folded to bring said perpendicular edge portions together second peel-apart lines of non-continuous adhesive are provided for sealing these edges together along their length in a manner enabling the edges thereof to be peeled apart, characterised in that a part of each parallel edge portion (30, 31) carries adhesive and a part of each parallel edge portion is void of adhesive such that when said parallel edge portions are brought together the adhesive parts on one edge register with the void parts on another edge to provide the substantially continuous first line of adhesive, and each of the sheets (23, 24) having along at least one of its perpendicular edge portions (33, 34) a non-continuous second line of adhesive therealong comprising discrete areas of adhesive separated by areas void of adhesive, arranged such that when the edges of the perpendicular edge portions are brought together the discrete areas of adhesive on one sheet register with void areas on another sheet to provide the non-continuous second lines of adhesive, the spacing between said spaced apart discreet areas of adhesive of the non-continuous lines being such that when the perpendicular potions (33, 34) are brought together the total area free of adhesive along each non-continuous adhesive line is at least twice the total area covered by such adhesive. A business form assembly according to claim 1 characterised in that each parallel edge portion (30, 31) carries a line of adhesive extending continuously a distance equal to about one half the length thereof and being void of adhesive for the other substantially one half thereof. A business form assembly according to claim 2 characterised in that each of the sheets (23, 24) carries a line of non-continuous adhesive extending along one of its perpendicular edge portions (33, 34) for substantially the full length of that edge portion and the other of its perpendicular edge portions is void of adhesive. A business form assembly according to claim 1 or claim 2 characterised in that the areas of peel-apart adhesive on one sheet of each unit along each perpendicular edge portion (33, 34) are interspaced between the areas of peel-apart adhesive on the other sheet of the unit when the unit is folded. A business form assembly according to any of claims 1 to 4 characterised in that said adhesive is a heat-activatable adhesive. A business form assembly according to any of claims 1 to 5 characterised in that in said non-continuous lines of adhesive said area free of adhesive is in the range of 3 to 9 times as great as the area covered by adhesive. A business form assembly according to claim 6 characterised in that said area free of adhesive is in the range of 4 to 5 times as great as the area covered by adhesive. A business form assembly according to any of claims 1 to 7 characterised in that the adhesive is arranged substantially symmetrically of each unit so that each sheet of the unit carries substantially half the adhesive. A sealed mailer formed from an assembly according to any of the preceding claims.

Inventors: PERRIMAN VICTOR, PERRIMAN, VICTOR
Applicants: MOORE BUSINESS FORMS INC, MOORE BUSINESS FORMS, INC.
Application year: 1992
Main classification: B42D5
IPC codes: B42D5