Abstract:
An envelope sheet assembly for stand-alone use, or for securing into a brochure or binder, includes multiple sheets overlying one another so that the assembly is of uniform thickness to facilitate laser, offset, flexograph printing or the like thereon. The envelope sheet assembly is preferably 8½ inches by 11 inches in size, and the envelope is preferably 11 inches by 4½ inches. Permanent pressure sensitive adhesive is employed to hold the sheets together and to form the envelope. The adhesive is also applied to the sealing flap, with a removable strip protecting the adhesive coated flap. The sheet assembly may frame the envelope at all outside edges of the envelope or some of the outer edges of the sheet assembly can form outer edges of the envelope.

Description:
FIELD OF THE INVENTION 
     This invention relates to mailer envelope sheets which may be separate from or included in a brochure, catalog, booklet, binder or the like. 
     BACKGROUND OF THE INVENTION 
     It has previously been proposed to include return mailer envelopes in brochures, see R. E. Katz U.S. Pat. No. 4,084,696 granted Apr. 18, 1978. However, the &#39;696 envelope sheet has certain drawbacks. For example, it has an envelope portion which is double thickness, while the remainder of the sheet is a single thickness of paper. For stacking and printing on sheets of paper, it is important that the paper be of uniform thickness to provide regular stacking and to avoid jamming of the copier. In addition, the &#39;696 patent has exposed adhesive which could be activated under high humidity or damp conditions. With exposed activated adhesive, sheets may stick together and laser or ink jet printers may jam or become contaminated. 
     Prior art return mailer envelope assemblies also fail to adequately protect the envelope during printing, binding and transportation. In prior art assemblies, envelope edges and corners are exposed and can become caught in machinery and bent or torn. Also, the envelope can take on a worn appearance after repeated flipping-through of the article such as a catalog, booklet or brochure into which it is bound. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is a principal object of the present invention to provide an envelope sheet assembly which has no exposed adhesive, and which will readily feed through high speed printers without jamming or contamination. It is a further object of the present invention to provide an envelope sheet assembly in which the outside edges and corners of the envelope are protected. The assembly is adapted for inclusion in a brochure, magazine or the like, but may also be used separately from such bound articles. 
     In one illustrative embodiment of the invention, the envelope sheet assembly is formed of three sheets and is of substantially uniform thickness for high speed printing. The envelope sheet assembly includes top, intermediate and base sheets of paper held together by adhesive. Perforations passing through the top and intermediate sheets form an envelope having a front layer formed from the top sheet and a back layer formed from the intermediate sheet. The back layer has inner and outer surfaces. The top, intermediate and base sheets of paper are of substantially the same size. A die-cut, with optional spaced ties, strikes through the base sheet and intermediate layer, forming a scored envelope sealing flap from the front layer of the envelope and a flap liner strip from the back layer of the envelope (intermediate assembly layer). A release coating is provided on the outer surface of the back layer and is aligned with a pressure sensitive adhesive layer on the surface of the base sheet so that the back layer removably adheres to the base sheet. A coating layer is provided on the inner surface of the back layer along the flap liner strip and is aligned with pressure sensitive adhesive areas on the envelope flap so that the flap liner removably adheres to the envelope flap. An adhesion region free of release material is located on the outer surface of the back layer adjacent to the flap liner for permitting adhesion of the flap to the outer surface of the back layer when sealing the envelope. The adhesion region is preferably substantially free of the silicone release material on the outer surface of the back layer. The adhesive layer on the surface of the base sheet substantially ends at the region of the base sheet aligned with the adhesion region. The envelope is permanently sealed along the bottom and two sides by adhesive on the front layer and inner surface of the back layer. When the envelope is to be closed by the user, the flap liner strip formed in the intermediate layer is stripped off and the adhesive coated flap is folded down onto the adhesion region of the back of the envelope. 
     The envelope sheet assembly preferably includes an envelope with a length greater than 8½ inches and a width greater than 4 inches for conveniently receiving a standard 8½×11 inches or an A-4 sheet folded three times. It is noted that these dimensions are for standard size 8½ inches by 11 inches, or A-4, sheets included in brochures, and for brochures or the like having different dimensions, the two layer envelope assembly would be correspondingly modified in its dimensions. As noted above, the envelope assembly can also be used stand-alone, without a brochure or the like. 
     The sheet assembly may also include one or more of the following additional features: (1) an envelope which is approximately 11 inches long; (2) the envelopes may be approximately 4 inches to 5 inches in height; (3) the individual sheets making up the three layer sheet assembly may be formed of fairly lightweight paper so that the sheets may be semi-translucent or semi-transparent; and (4) the inside surfaces of the envelope may be provided with a printed pattern to preclude reading enclosures through the envelope. 
     Other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description and from the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 shows a printable triple-layer mailer assembly of the present invention with the envelope partially removed from the assembly and the flap liner strip partially peeled off from the flap. 
     FIG. 2 shows the back side of the envelope with the flap liner strip partially peeled off from the flap. 
     FIG. 3 shows the remainder of the assembly after the envelope has been removed. 
     FIG. 4 shows a brochure which includes the printable triple-layer mailer assembly of FIG.  1 . 
     FIG. 5 shows an exploded view of an embodiment of the triple-layer mailer assembly. 
     FIG. 6 shows an embodiment of the triple-layer mailer assembly of the present invention including a mailer along with the envelope. 
     FIG. 7 shows an embodiment of the printable triple-layer mailer assembly of FIG. 1 with the perforations having a few widely spaced cuts and ties. 
     FIG. 8 shows an embodiment of the printable triple-layer mailer assembly of FIG. 1 having a bold printed pattern on the inside surfaces of the envelope to preclude reading enclosures through the envelope. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIG. 1 shows an envelope  110  partially removed from the envelope assembly  112 . A flap liner strip  136  is shown partially peeled off from a sealing flap  134 . The envelope sheet assembly includes top  114 , intermediate  116  and base  118  sheets of paper held together by adhesive  120  (also see FIG.  5 ). The top  114 , intermediate  116  and base  118  sheets may have the same predetermined standard size, such as 8 ½×11 inches, A-4 or legal size paper. 
     Die-cuts or perforations  122  passing through the top  114  and intermediate  116  sheets form the envelope  110  having a front layer  124  formed from the top sheet  114  and a back layer  126  formed from the intermediate sheet  116 . The perforations  122  ran be fully or cleanly die cut (see FIG. 1) or alternatively can have a few widely spaced cuts  123  and ties  125  (see FIG.  7 ). The perforations  122  passing through the top sheet  114  form the front layer  124  of the envelope including the sealing flap  134 . The back layer of the envelope  126  has inner  128  (see FIG. 5) and outer  130  surfaces. The sealing flap  134  may have a score line  138 . The sealing flap  134  is folded along the score line  138  when folding the sealing flap  134  to the back layer  126 . The perforations  122  passing through the intermediate sheet  116  can be fully cut to form the back layer  126  of the envelope  110  and the separate flap liner  136  for covering the sealing flap  134  of the envelope  110 . The perforations  122  passing through the intermediate sheet  116  can alternatively consist of a cut and tie pattern die cut to form the back layer  126  of the envelope  110  and the separate flap liner  136  for covering the sealing flap  134  of the envelope  110 . Die-cut perforations  132  strike through the base sheet  118  and back layer  116  to form the score line  138  at the bottom of the sealing flap  134  and to form the flap liner  136  from the back layer  126  of the envelope  110 . 
     A releasable layer  140  (see FIG. 2) is formed on the outer surface  130  of the back layer  126  and is aligned with a pressure sensitive adhesive layer  142  (see FIG. 3) on the surface of the base sheet  118  so that the back layer  126  removably adheres to the base sheet  118 . The releasable layer  140  can include of a plurality of silicone segments  144 . The pressure adhesive layer  142  can include of a plurality of adhesive segments  146  as well as areas of the adhesive  120  on the base sheet  118  proximate the edges of the envelope. Each of the silicone segments  144  positioned on the back layer is positioned to overlap one of the corresponding adhesive segments  146  positioned on the base sheet  118 . With some types of adhesive and paper, the silicone on the releasable layer  140  is unnecessary because even without the silicone, the envelope is securely held to the base sheet  118 , yet is easily peeled away from the adhesive layer  142 . 
     The sealing flap  134  has an adhesive layer  150  for adhering to the back layer  126  when the flap  134  is folded down along the score line  138 , thereby sealing the top of the envelope  110 . The flap liner  136  covers the sealing flap  134  of the envelope  110 . A silicone release layer  148 , is formed on the inner surface of the back layer  126  along the flap liner  136  and is aligned with the pressure sensitive adhesive layer  150  on the envelope flap  134  so that the flap liner  136  removably adheres to the envelope flap  134 . An adhesion region  152  is formed on the outer surface  130  of the back layer  126  adjacent to the flap liner  136  for permitting adhesion of the adhesive layer  150  of the flap  134  to the outer surface of the back layer when sealing the envelope  110  (see also FIG.  2 ). The adhesion region  152  forms a gap in the releasable layer  140  in the region below the flap liner  136 . The adhesion region  152  need not be entirely free of the silicone segments  144  forming release layer  140 , but must at least present enough release-layer-free surface so that the adhesive layer  150  can securely adhere to the outer surface  130  of the back layer  126 . 
     The adhesive force between the sealing flap  134  and the flap liner  136  should be greater than the adhesive force between the base sheet  118  and the flap liner  136  so that when the envelope  110  is peeled away from the envelope assembly  112 , the flap liner  136  remains adhering to the sealing flap  134 . Also, the adhesive layer  142  should hold the envelope securely to the envelope assembly so that the envelope will not become disengaged when being fed though various printing devices when printing on the front layer  124  of the envelope  110 . The envelope  110  is also held securely enough so that it will not become accidentally disengaged from the envelope assembly  112  when handling a brochure or binder into which the envelope assembly  112  has been bound. On the other hand, the adhesive layer  142  allows for easy manual removal of the envelope  110  from the envelope assembly  112  without damage to the envelope  110  by peeling the envelope  112  from the base sheet  118 . 
     FIG. 2 more clearly shows the back of the envelope  110 . The envelope  110  has been peeled off from the remainder of the envelope assembly  112 . The flap liner strip  136  is shown partially peeled off from the flap  134 . Also shown are the silicone segments  144  forming the releasable layer  140 . The adhesion region  152  without the silicone segments  144  is shown as well. 
     FIG. 3 shows the remainder of the envelope assembly  112  after the envelope  110  has been peeled away as shown in FIG.  2 . The adhesive layer  142  is shown formed of areas of the adhesive  120  as well as the adhesive segments  146 . The base sheet  118  has a substantially adhesive-free region  158 . The adhesive-free region  158  is aligned with the adhesion region  152 , so that the adhesive layer  142  will not stick to the unprotected adhesion region  152 . In some embodiments, when special adhesive or paper is used, it is unnecessary to use the adhesive-free region  158  because the envelope can be peeled from the adhesive layer  142  even with the adhesive layer  142  adhering to the adhesion layer  152 . 
     FIG. 4 shows the envelope assembly  112  bound in an article  160 . The envelope  110  is framed and held firmly by the assembly  112  so that the envelope will not become accidentally disengaged when binding or during mailing or use of brochure  160 . The assembly  112  also protects the envelope outside corners and edges from tearing or fraying during binding, mailing or use. The article  160  can be a book, magazine, catalog, mailer or other articles into which the envelope assembly  112  can be bound. Additionally, the envelope assembly  112  and be used in a stand alone configuration without the article  160 . 
     FIG. 5 shows an exploded view of the envelope assembly  112 . The envelope assembly  112  is made from the top sheet  114 , the intermediate sheet  116  and the base sheet  118 . The sheets are held together by the adhesive  120 . The outer edges of the sheets are coated with pressure sensitive adhesive. The adhesive  120  extends from the outer edges of each sheet and across the perforations  122  to the area within the front layer  124  and back layer  126 . In this way, the envelope  110  is sealed on three sides and the envelope assembly  112  is secured on four sides. Vents or gaps  162  in the adhesive  120 ,  150  allow air to pass between the inside and outside of envelope  42 . The gaps can be wider than {fraction (1/32)} inch, for example. The inner surface of the top sheet  114  (not shown) may also have adhesive  120  with vents  162  having the same spatial arrangement as the adhesive  120  and vents  162  illustrated coating the edges of the intermediate sheet  116 . Thus, the adhesive  120  and vents  162  on the top sheet  114  and intermediate sheet  116  match each other to secure the two sheets together. 
     FIG. 6 shows an embodiment of the triple-layer mailer assembly of the present invention including a mailer  164  along with the envelope  110 . The mailer  164  can be a letter, a contract or an order form, for example. As in the embodiment of FIG. 1, the envelope  110  is formed by the perforations  122 . In the present embodiment, the mailer  164  is also formed in the top sheet  114  by perforations  166 . The mailer  164  can be one or more pages and is held within the assembly  112  by adhesive. When the mailer  164  has multiple pages, one page can be formed from the top sheet  114 , a second page from the intermediate sheet  116  and a third page from the base sheet. 
     Inside the envelope front  124  and back  126  layers, on the front layer inner surface and the back layer inner surface  128 , can be bold printed patterns  127  as illustrated schematically in FIG.  8 . For easy printing using xerographic or ink jet printers, it is desirable that the envelope assembly  112  be relatively thin and flexible. As a result, the paper forming the front and back of the envelope may be semi-translucent or semi-transparent, so the bold printed pattern  127  is useful to preclude reading of material enclosed within the envelope. By way of example, 20 pound paper may be used for each sheet of the two sheet assembly. When the term “20 pound paper” is used, it means that 500 sheets of paper 17 inches by 22 inches in size, weighs 20 pounds. Incidentally, while any pressure sensitive adhesive may be used, rubber based, hot melt permanent pressure sensitive adhesive is preferred. 
     Concerning dimensions, each of the sheets of the envelope assembly  112  may be 8½×11 inches, or A-4 size paper. The bottom and two sides of the envelope  110  are bonded together by permanent adhesive, which may be the same pressure sensitive adhesive used on the sealing flap of the envelope. The envelopes are preferably 11 inches in length and between 4 and 5 inches, preferably about 4½ inches, in height. Thus, a height of at least 4 inches and a length of at least 9 inches for the envelopes is desired. 
     In conclusion, it is to be understood that the foregoing detailed description and accompanying drawings are illustrative of the principles of the invention. Various changes and modifications may be employed, for example, different sizes of paper such as 8½×14 inches, or other sizes and weights of paper may be employed, with envelope size being accordingly modified. Additionally, more than three sheets can be used in forming the envelope assembly. For example, four sheets of paper can be secured together to form a three layer envelope sheet assembly. Accordingly, the invention is not limited to the specific embodiments described and shown in the drawings.