TWELVE INCH PRESSURE SEAL FORM PRODUCT

Abstract: A pressure seal mailer type business form (10) is made from an intermediate substantially twelve inches long, and capable of being constructed with either V-fold, C-fold or Z-fold configurations. The intermediates may be fed from a stack to a conventional laser printer. The provision of the twelve inch length allows for numerous advantages while still meeting USPS guidelines.

Description: TWELVE INCH PRESSURE SEAL FORM PRODUCT BACKGROUND AND SUMMARY OF THE INVENTION The invention relates to an improvement in an intermediate for a mailer type business form, the mailer so produced, and a method of manufacture thereof, which have advantages under a number of circumstances. The invention may be implemented with any conventional type of Z-fold, C-fold, or V-fold construction, some of which are disclosed in U.S. patents 5,785,242, 5,553,774, 5,513,795, 5,253,798, 5,201 ,464, and 5,366,145, the disclosures of which are hereby incorporated by reference herein. Conventional pressure seal mailer type business forms (that is those using pressure activated cohesive such as disclosed in U.S. patent 4,918,128) are typically in either eleven inch or fourteen inch lengths in practice. There are a number of applications where the eleven inch length is not suitable, but the fourteen inch length is also unsuitable because of much slower printing speeds and higher processing times. Oftentimes it is not possible to adapt the eleven inch forms to such uses since there are postal issues dealing with bar codes being applied to the form in postal recognized areas, adequate sealing, and the like. Also, there are some circumstances where checks are included as part of the mailer, and the checks do not have the desired dimensions if the conventional eleven inch form length is utilized. According to the present invention an intermediate for a mailer type business form, and the method of utilization thereof, and the final mailer produced thereby, are provided which overcome the problems in the prior art in yet a simple yet effective manner. According to the invention, the length of the intermediate is substantially exactly twelve inches (that is twelve inches give or take typical manufacturing tolerances, which rarely are more than .05 inches, and never more than .1 inch). This modest increase in the length of the intermediate has a number of unexpected and desirable advantages. For V-fold constructions, the additional one inch space that is provided (compared to the eleven inch form) provides additional space for variable imaging such as remittances, messages, statements, and the like. Also, this allows the production of a form which - when the final mailer is opened up -- has a substantially conventional eleven inch letter size length configuration of the printed area (once the tear-off strips are removed) that allows the f DΠTI to fit into industry standard binders and folders. Also, this allows for bigger inserts, ε nd more room for fixing labels or cards, and easily complies with United States Postal Service postal regulations for both range of depth and width. When the construction according to the invention is used in a C-fold or Z-fold configuration, it gives each panel V 3 inch more usable space for imaging, allows for a larger check for payroll applications (e.g. 3 7 Λ 6 inches by 7 Vz inches), allows for better placement of bar coding required for PCC and job sorting options without interfering with USPS postal guidelines, and provides for larger inserts or more room for affixing labels or cards. The intermediates may also have eccentric Z- or eccentric C-fold configurations too. According to one aspect of the present invention a mailer type business form intermediate is provided comprising the following: A substantially quadrate cut sheet of paper having first and second faces, top and bottom edges substantially parallel to each other, and first and second side edges substantially perpendicular to the top and bottom edges and substantially parallel to each other. The top and bottom edges spaced a first distance, and the side edges spaced a second distance, less than the first distance. First and second lines of weakness formed in the sheet adjacent, but spaced from and substantially parallel to, the first and second side edges, respectively, to define first and second removable side margin portions. At least a first fold line formed in the sheet substantially parallel to the top and bottom edges, and defining the sheet into panels on opposite sides thereof. At least one pattern of pressure activated cohesive in the side margins on at least one of the faces, the patterns for holding the sheet in a folded configuration as a mailer. And the first and second side edges having a length substantially equal to twelve inches. While the intermediate may having varying widths, and the preferred embodiment has a width of substantially equal to 8 V-≥ inches (that is 8 V≥- inches within conventional tolerances); that is the top and bottom edges have a length of substantially equal to 8 Λ h inches. This allows for maximum utilization in laser printers or the like. For the V-fold embodiment, the at least one fold line comprises a single fold line substantially half way between the top and bottom edges, and the pressure activated cohesive patterns are provided on only one the first face, so that the intermediate forms a V-fold mailer. Preferably the intermediate further comprises third and fourth lines of weakness substantially parallel to the top and bottom edges, and wherein the third and fourth lines of weakness are spaced substantially eleven inches from each other. The intermediate typically also includes an outgoing mailing address imaged on the second face. For the C-fold and Z-fold configurations the at least one fold line comprises first and second fold lines spaced to define three (e,.g, substantially equal size) panels. Where eccentric Z- or C-folds are provided, then two of the panels are typically of substantially equal size and the third is of lesser size. For a C-fold construction, the pressure sensitive cohesive patterns are placed so that the intermediate comprises a C-fold mailer when C-folded about the fold lines, and the cohesive would hold the panels in a final sealed mailer. For the Z-fold construction the pressure sensitive cohesive patterns are placed so that the intermediate comprises a Z-fold mailer when Z-folded about the fold lines, and the cohesive would hold the panels in a final sealed mailer. Also in the Z- and C-fold constructions, the intermediate preferably further comprises third, fourth and fifth lines of weakness parallel to the top and bottom edges, and cooperating pressure activated cohesive patterns adjacent at least two of the third, fourth and fifth lines of weakness. According to another aspect of the present invention a method of printing a mailer in a laser printer is provided comprising (a) placing a plurality of intermediates as described above in a stack; and (b) feeding the intermediates one at a time to the laser printer, and laser printing at least variable information on the intermediates with the printer. For the V-fold configuration, the method further comprises (c) V-folding the intermediates and applying at least about one hundred pounds per lineal inch to the cohesive patterns to effect sealing of the intermediates into V-fold mailers. For the C- fold construction the method further comprises (c) C-folding the intermediates and applying at least about one hundred pounds per lineal inch to the cohesive patterns to effect sealing of the intermediates into C-fold mailers. For the Z-fold construction the method further comprises (c) Z-foIding the intermediates and applying at least about one hundred pounds per lineal inch to the cohesive patterns to effect sealing of the intermediates into Z-fold mailers. The C- or Z-folding may be eccentric C- or Z-folding. The invention also relates to a mailer produced according to the methods described above, and utilizing the intermediates described above. It is the primary object of the present invention to provide an advantageous intermediate, mailer type business form produced therefrom, and a method of utilization thereof. This and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a top plan view of an exemplary Z-fold mailer type business form intermediate according to the present invention; FIGURE 2 is schematic perspective view showing the intermediate of FIGURE 1 being Z-folded into a mailer configuration; FIGURE 3 is a top plan view of the inside (after the final mailer is constructed) face of a V-fold mailer type business form intermediate according to the present invention; FIGURE 4 is a schematic view showing the intermediate of FIGURE 3 being V-folded to form a mailer; FIGURES 5 and 6 are views like those of FIGURES 1 and 2 for a C-fold intermediate and mailer; and FIGURE 7 is a schematic view showing the utilization of the intermediates of FIGURES 1 , 3, and 5 in the production of a final mailer according to the present invention. DETAILED DESCRIPTION OF THE DRAWINGS FIGURE 1 illustrates a mailer type business form intermediate shown generally by reference numeral 10 which comprises a substantially quadrate cut sheet of paper. The sheet of paper forming the intermediate 10 has a first face 1 1 seen in FIGURE 1 , and a second 12 (see FIGURE 2) opposite the first face. The sheet of paper forming the intermediate 10 also has top and bottom edges 13, 14, respectively, substantially parallel to each other, and first and second side edges 15, 16, respectively, substantially parallel to each other and substantially perpendicular to the top and bottom edges 13, 14. The top and bottom edges 13, 14 are spaced a first distance 17 while the side edges 15, 16 are spaced a second distance 18, the distance 18 being less than the distance 17. According to the present invention the distance 17 is substantially equal to twelve inches, that is twelve inches or other values within the manufacturing tolerances for twelve inches. While the distance 18 (the width of the sheet of paper forming the intermediate 10) may vary, preferably it is substantially equal to 8 1 /2 inches (that is 8 Vi inches or manufacturing tolerance variations thereof). The intermediate 10 also comprises first and second lines of weakness 19, 20, respectively, such as perforation lines, formed in the sheet of paper adjacent, but spaced from, and substantially parallel to, the side edges 15, 16, respectively, to define first and second removable side margin portions 21 , 22. At least a first fold line 23 is formed in the sheet substantially parallel to the top and bottom edges 13, 14 in defining the sheet into panels into opposite sides thereof. In the Z-fold configuration illustrated in FIGURE 1 , a second fold line 24 is provided, and three panels are defined, 25, 26, and 27. The intermediate 10 also comprises patterns of pressure activated cohesive (such as described in U.S. patent 5,201 ,464, which has been incorporated by reference herein) in the side margin portions 21 , 22 on at least one of the faces 11 , 12. These patterns are for holding the sheet forming the intermediate 10 in a folded configuration as the final mailer, the sheet 10 being Z-folded to form a mailer illustrated in FIGURE 2, and a final end mailer being schematically illustrated at 28 in FIGURE 7. The patterns may comprise any configuration such as lines, spots, dots, bars, strips, discontinuous or continuous, or any other suitable configuration. The patterns of cohesive are placed in the side margins 21 , 22, and perhaps elsewhere, depending upon the exact construction of the final mailer. Representative cohesive patterns, in the form of spaced blocks, are illustrated schematically at 29 for the first face 1 1 in FIGURE 1 , and at 30 for the second 12 in FIGURE 2, the particular arrangement of the patterns 29, 30 being per se preferably entirely conventional. For the Z-fold configuration illustrated in FIGURES 1 and 2, it is preferred that there also be third, fourth, and fifth lines of weakness, indicated schematically at 31 through 33, respectively, in FIGURE 1 , which are parallel to but spaced from the top edge 13, and the second fold line 24, as illustrated. These lines of weakness define other tear-off strips associated with patterns 29 extending generally parallel to edges 13, 14. For the construction of FIGURES 1 and 2, an outgoing address 35, including a bar code 36, is provided on the face 1 1 in the first panel 25, and a return address 37 also is preferably provided therein. FIGURES 3 and 4 illus.rate an intermediate like that of FIGURES 1 and 2 only having a V-fold construction. In the embodiment illustrated in FIGURES 3 and 4 components comparable to those >n the FIGURES 1 and 2 embodiments are shown by the same reference numeral only preceded by a "1 ". Note that in this embodiment there is only a single fold line 123, and that the third and fourth lines of weakness 131 , 132 are adjacent but spaced from the top and bottom edges 1 13, 1 14, respectively, and the lines of weakness 131 , 132 are spaced a distance 40 which is substantially exactly eleven inches (eleven inches given conventional tolerances), in the preferred embodiment. In this embodiment because a V-fold construction is provided, patterns of cohesive 129 are provided only on the second face 1 12, and an outgoing address 135, 136 is provided on the first face 11 1. The FIGURES 5 and 6 embodiment is a C-fold construction the components therein comparable to those in the FIGURES 1 and 2 embodiment are shown by the same reference numeral only preceded by a "2". The basic difference between the intermediate 210 and the intermediate 10 is the placement of the pressure activated cohesive patterns 229, 230, the panels 225-227 being C-folded as illustrated in FIGURE 6. In all of the embodiments of FIGURES 1 through 6 indicia may be provided wherever desired on the panels, and preferably at least on all of the panels internal of the final mailer 28 produced. FIGURE 7 schematically illustrates a method of producing a mailer 28 according to the present invention utilizing a conventional laser printer 42. A plurality of the intermediates 10, 110, or 210 are placed in a stack 43 as schematically illustrated in FIGURE 7, preferably the stack 43 being provided within a conventional tray 44 for the laser printer 42. A conventional tray 44 will fit the twelve inch length 17, 117, 217 of the intermediates 10, 1 10, 210 under the majority of circumstances, and the printing with laser printer 42 will be much faster (as much as 50% faster) than if a fourteen inch form were used. The intermediates 10, 1 10, 210 are then fed one at a time to the laser printer 42 and they are laser printed, with all variable information, which typically includes the outgoing address 35, 36, 135, 136, 235, 236, as well as any other variable information desired; and/or some or all of the non-variable information in addition to the variable information may be printed using the laser printer 42. Subsequent to printing, the printed intermediate 10, 1 10, 210 is fed to a conventional folder 45, such as conventional folder for a Moore pressure sealer such as a PS-1 , etc. available from Moore North America, Inc. of Lake Forest, Illinois. The folder 45, depending upon the intermediate 10, 110, 210, either V-, C-, eccentric C-, eccentric Z-, or Z-folds the intermediate, and then substantially immediately thereafter seals as indicated by the sealer 46. Typically the folder 45 and sealer 46 are part of the same piece of equipment such as described above and available from Moore, although they can be separate pieces of equipment. Sealer 46 may either be of the steam roller type where it engages the entire folded intermediate, or of the type having only edge sealing, where the patterns 29, 30, 129, 229, 230 are located. The sealer 46 typically applies a sealing force of at least 100 pounds per lineal inch, preferably at least 200 pounds per lineal inch. As is conventional, inserts may be provided with the intermediates 10, 1 10, 210, inserted during folding with the folder 45, or just prior to sealing with the sealer 46. Also, the intermediates may have constructions which include reply envelopes, such as shown in U.S. patent 5,201 ,464. It will thus be seen that according to the present invention a highly advantageous mailer type business form intermediate, and method of producing a mailer using a laser printer associated therewith, and the mailer produced therefrom, are provided. While the invention has been herein shown and described in what is presently conceived to be the most practical and preferred embodiment, it will be apparent those ordinary skill in the art that many modifications may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent products and methods.

Claims: WHAT IS CLAIMED IS: 1 . A mailer type business form intermediate comprising: a substantially quadrate cut sheet of paper having first and second faces, top and bottom edges substantially parallel to each other, and first and second side edges substantially perpendicular to said top and bottom edges and substantially parallel to each other; said top and bottom edges spaced a first distance, and said side edges spaced a second distance, less than said first distance; first and second lines of weakness formed in said sheet adjacent, but spaced from and substantially parallel to, said first and second side edges, respectively, to define first and second removable side margin portions; at least a first fold line formed in said sheet substantially parallel to said top and bottom edges, and defining said sheet into panels on opposite sides thereof; at least one pattern of pressure activated cohesive in said side margins on at least one of said faces, said patterns for holding said sheet in a folded configuration as a mailer; and said first and second side edges having a length substantially equal to twelve inches. 2. An intermediate as recited in claim 1 wherein said top and bottom edges have a length of substantially equal to eight and one-half inches. 3. An intermediate as recited in claim 2 wherein said at least one fold line comprises a single fold line substantially half way between said top and bottom edges, and wherein said pressure activated cohesive patterns are provided on only one said first face, so that said intermediate forms a V-fold mailer. 4. An intermediate as recited in claim 3 further comprising third and fourth lines of weakness substantially parallel to said top and bottom edges, and wherein said third and fourth lines of weakness are spaced substantially eleven inches from each other. 5. An intermediate as recited in claim 3 wherein an outgoing mailing address is imaged on said second face. 6. An intermediate as recited in claim 1 wherein said at least one fold line comprises a single fold line substantially half way between said top and bottom edges, and wherein said pressure activated cohesive patterns are provided on only one said first face, so that said intermediate forms a V-fold mailer. 7. An intermediate as recited in claim 6 further comprising third and fourth lines of weakness substantially parallel to said top and bottom edges, and wherein said third and fourth lines of weakness are spaced substantially eleven inches from each other. 8. An intermediate as recited in claim 1 wherein said at least one fold line comprises first and second fold lines, spaced to define three panels. 9. An intermediate as recited in claim 8 wherein said pressure sensitive cohesive patterns are placed so that said intermediate comprises a C-fold mailer when C-folded about said fold lines, and said cohesive holds said panels in a final sealed mailer. 10. An intermediate as recited in claim 8 wherein said pressure sensitive cohesive patterns are placed so that said intermediate comprises a Z-fold mailer when Z-folded about said fold lines, and said cohesive holds said panels in a final sealed mailer. 1 1. An intermediate as recited in claim 9 wherein said top and bottom edges have a length of substantially equal to eight and one-half inches. 12. An intermediate as recited in claim 10 wherein said top and bottom edges have a length of substantially equal to eight and one-half inches. 13. An intermediate as recited in claim 8 further comprising third, fourth and fifth lines of weakness parallel to said top and bottom edges, and cooperating pressure activated cohesive patterns adjacent at least two of said third, fourth and fifth lines of weakness. 14. An intermediate as recited in claim 9 further comprising third, fourth and fifth lines of weakness parallel to said top and bottom edges, and cooperating pressure activated cohesive patterns adjacent at least two of said third, fourth and fifth lines of weakness. 15. An intermediate as recited in claim 10 further comprising third, fourth and fifth lines of weakness parallel to said top and bottom edges, and cooperating pressure activated cohesive patterns adjacent at least two of said third, fourth and fifth lines of weakness. 16. A method of producing a mailer using a laser printer comprising: (a) placing a plurality of intermediates as recited in claim 1 in a stack; and (b) feeding the intermediates one at a time to the laser printer, and laser printing at least variable information on the intermediates with the printer. 17. A method as recited in claim 16 using intermediates as recited in claim 3; and further comprising after (b), (c) V-folding the intermediates and applying at least about one hundred pounds per lineal inch to the cohesive patterns to effect sealing of the intermediates into V-fold mailers. 18. A method as recited in claim 16 using intermediates as recited in claim 9; and further comprising after (b), (c) C-folding the intermediates and applying at least about one hundred pounds per lineal inch to the cohesive patterns to effect sealing of the intermediates into C-fold mailers. 19. A method as recited in claim 16 using intermediates as recited in claim 10; and further comprising after (b), (c) Z-folding the intermediates and applying at least about one hundred pounds per lineal inch to the cohesive patterns to effect sealing of the intermediates into Z-fold mailers. 20. A mailer produced according to the method of claim 16.

Inventors: LOMBARDO LEO, LOMBARDO, LEO
Applicants: MOORE NORTH AMERICA INC, MOORE NORTH AMERICA, INC.
Application year: 2000
Main classification: B42D5
IPC codes: B42D15, B65D27, B65H45