Abstract:
A self-mailer construction that creates a single- or double-panel inside a carrier. Die-cuts are positioned in such as way as to reduce the size of at least one internal panel. Because these panel(s) are narrow-width, they terminate short of the full-width portion of the outside panels and, therefore, are unattached at any point other than the top edge of the sealed document. Accordingly, when the mailer is engaged with an envelope slitter or similar device, the truncated panel becomes free-floating and can be readily removed.

Description:
BACKGROUND AND SUMMARY OF THE INVENTION  
         [0001]    The present invention relates to a self-mailer construction and, more particularly, to a self-mailer construction that lends itself to being opened by means of automated letter openers.  
           [0002]    While self-mailers have proven to be very popular medium for preparing both negotiable and non-negotiable documents for the mail stream, the intended recipient of these documents has been, traditionally, individual businesses or customers. As such, the normal opening method employed for these forms has been perfectly adequate. That is, an opening method that requires the recipient to manually remove strips, or margins, around the perimeter of the form. When opening an individual document, such as a payroll check, or notice, this opening method does not create any significant difficulty.  
           [0003]    In the bill payment and presentment industry, however, the documents prepared are more typically submitted to a large remittance processing operation, such as those operated by the banking industry. In this arena, thousands of documents are submitted to a single processing location. Upon receiving these individual documents, the remittance processing facility uses automated equipment to remove one or more edges of the mail piece (typically an envelope). The content of the mail piece are then extracted, by hand or mechanically, and then forwarded to automated reading and sorting equipment, such as an OCR or MICR scanner. A familiar example of this operation would be the processing of payments for an individual&#39;s credit card account. Without the ability to automate this process, the handling of these documents would be extremely cumbersome and very costly.  
           [0004]    Conventionally, self-mailers have not been compatible with automated processing systems and have, therefore, not been an alternative.  
           [0005]    The present invention provides a mailer construction that overcomes these limitations by utilizing a unique manufacturing method to incorporate a series of die-cuts on a form so that after folding and sealing, the contents inside the self-mailer can be easily extracted using automated equipment, as with a conventional envelope.  
           [0006]    More particularly, the self-mailer construction described herein creates a single- or double-panel inside a carrier, depending on whether a letter-fold (C-fold) or a double parallel fold (Double V-Fold) is utilized. Die-cuts are positioned in such as way as to reduce the size of at least one internal panel to make it free-floating once an envelope slitter or similar device passes across the top edge of the document. Because these panel(s) are narrow-width, they terminate short of the full-width portion of the outside panels and, therefore, are unattached at any point other than the top edge of the sealed document. Accordingly, when the mailer is engaged with an envelope slitter or similar device, the truncated panel becomes free-floating and can be readily removed.  
           [0007]    In a presently preferred embodiment, all imaging or personalization is designed to be accomplished on one side of the document, in order to minimize the time required for a computer to print the form. It is to be understood, however, that the document may be imaged on both sides, if needed, and if the printer includes such capabilities.  
           [0008]    Thus, the invention may be embodied in an intermediate for a mailer-type business form, comprising: a quadrate sheet of paper having parallel top and bottom edges, parallel first and second side edges perpendicular to the top edge, and first and second faces; and at least first and second fold lines parallel to said top and bottom edges dividing said sheet into at least first, second, and third panels, said first and second panels having substantially a same size and said third panel having a height and width less than said first and second panels. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    These and other objects and advantages of this invention, will be more completely understood and appreciated by careful study of the following more detailed description of the presently preferred exemplary embodiments of the invention taken in conjunction with the accompanying drawings, in which:  
         [0010]    [0010]FIG. 1 is a top plan view of a first face of an exemplary intermediate according to the present invention;  
         [0011]    [0011]FIG. 2 is a plan view of the second face of the intermediate of FIG. 1;  
         [0012]    [0012]FIG. 3 is a perspective view showing the intermediate of FIGS. 1 and 2 being folded into a mailer-type business form;  
         [0013]    [0013]FIG. 4 is a perspective view showing a mailer of the type illustrated in FIG. 2 being slitted by an automated slitter;  
         [0014]    [0014]FIG. 5 is an exploded perspective view showing the removal of a statement or check from the opened envelope according to an exemplary embodiment of the invention;  
         [0015]    [0015]FIG. 6 is a perspective view showing the opening of the mailer of FIG. 3 by the end user without a slitter;  
         [0016]    [0016]FIG. 7 is a perspective view showing the removal of a statement or check from the opened envelope of FIG. 6;  
         [0017]    [0017]FIG. 8 is a top plan view of a first face of an alternate intermediate according the present invention;  
         [0018]    [0018]FIG. 9 is a plan view of the second face of the intermediate of FIG. 8;  
         [0019]    [0019]FIG. 10 is a perspective view showing the intermediate of FIGS. 8-9 being folded into a mailer type business form according to a first folding alternative; and  
         [0020]    [0020]FIG. 11 is a perspective view showing the intermediate of FIGS. 8-9 being folded into a mailer type business form according to a second folding alternative. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    An exemplary intermediate for a mailer-type business form is shown generally by reference number  10  in FIGS. 1 and 2. It includes a quadrate sheet of substantially opaque paper having parallel top and bottom edges  12 , 14  and parallel first and second side edges  16 , 18 , respectively. The side edges are perpendicular to the top edge. The sheet further defines first and second faces  20 , 22 , FIGS. 1 and 2, respectively. First and second fold lines  24 , 26  are provided parallel to the top and bottom edges for dividing the sheet into three panels. The first and second panels  28 , 30  are substantially equal size. According to an exemplary embodiment of the invention, however, the fold lines  24 ,  26  are disposed and/or the bottom edge  14  of the intermediate is die cut so that the third panel  32  has a width, defined between the second fold line  26  and the bottom edge  14 , that is less the width of either of the first and second panels  28 ,  30 , as described in greater detail hereinbelow. Furthermore, the intermediate is die-cut during the manufacturing process, most preferably after printing and before folding, along lines  34 ,  36 , as shown in FIGS. 1 and 2 to truncate the length of the third panel, as also described in greater detail hereinbelow.  
         [0022]    With reference to the presently preferred, illustrated embodiment, the first panel  28  is disposed as the top panel of the form, the second panel  30  is disposed as the middle panel and the third panel  32  is disposed as the bottom panel of the form so that the second panel is between the first and third panels. Thus, the first panel is between the top edge  12  and first fold line  24 , the second panel is between fold lines  24  and  26  and the third panel is between fold line  26  and bottom edge  14  of the intermediate  10 . Fold lines  24 , 26  may comprise lines of weakness such as perforation lines or die cut lines or may merely be scored or crease lines. In the presently preferred embodiment, where the third panel  32  is adapted to be removed and retained by the end user, fold line  26  is preferably a line of weakness that facilitates separation of the third panel from the second panel. Furthermore, in a presently preferred embodiment, the first and second panels together define the outgoing envelope and, therefore, the first fold line  24  need not be adapted to be severed by the end user. As will become apparent below, the invention is not limited to the described series and orientations of panels, except as required by the appended claims.  
         [0023]    The intermediate also includes an outgoing address area  38  on the first face of the first panel. The outgoing address area  38  is of a size and adapted to receive, e.g., a laser printed address or pre-printed address label. The outgoing address area can include indicia corners or other indicator such as a change in texture, tone or color of the paper to facilitate the determination of the proper location of the outgoing address. Such indicators, however, are not critical to the implementation of the invention. Human readable address indicia, as shown only schematically by indicia  40  in FIG. 1 is ultimately provided on the intermediate, for example as it is passed through a printer. Other human or machine readable indicia may also be printed or pre-printed on the first face of the first panel, such as postal address bar coding (not shown), indicia  42  for postal stamp application and/or indicia  44  for the sender&#39;s return address. It is to be understood that since the first and second panels together define the out-going envelope, rather than providing the outgoing address, postal and return address indicia on the first face of the first panel, such indicia may be provided on the first face of the second panel  30 , upside down relative to the orientation provided in the illustrated embodiment on the first panel  28 , without departing from this invention.  
         [0024]    In the illustrated embodiment, the third panel  32  is configured as a negotiable instrument, such as a check, and thus advantageously includes human or machine readable indicia preprinted on the first and/or second face of the third panel and variably imaged indicia identifying, for example the payee and the amount paid. In the illustrated and presently preferred embodiment, the mailer is adapted so that all imaging or personalization is accomplished on one side of the document in order to minimize the time required to computer print the form. It is to be understood, however, that the document can be imaged on both sides, if desired.  
         [0025]    A first line of weakness  46  is formed in the first and second panels  28 ,  30  parallel to and spaced from the first side edge  16 . The first line of weakness defines a tear off strip  58  provided for readily opening one side of a mailer constructed by C-folding the intermediate about fold lines  24 , 26 . A second line of weakness  48  is further formed on the first and second panels parallel to and spaced from the second side edge  18 . The second line of weakness defines a tear off strip  60  providing for ready opening of the other side of the mailer constructed by C-folding the intermediate about fold lines  24  and  26  as shown in FIG. 3.  
         [0026]    Though not illustrated in detail, where the third panel  32  is defined as a negotiable instrument, such as a check, the intermediate is preferably provided so that the third panel contains multiple fraud deterrent security features. Further, for security and to obscure the check adapted to be contained in the mailer, the second face of the first and second panels preferably are preprinted with security screening as shown at  50  and  52 . It is to be understood, however, that the bottom, separable panel need not be a check, but can be printed as an invoice, statement, receipt, or offer informational or commercial document.  
         [0027]    The intermediate further comprises a first plurality of adhesive patterns  54 ,  55  provided along at least some of the edges of the panels for holding the first and second panels together in the outgoing mailer configuration when the sheet is C-folded about fold lines  24 , 26  as illustrated in FIG. 3. In the illustrated embodiment, the first adhesive patterns  54 ,  56  include elongated strips provided on the second face  22  of the first and/or second panels in the tear off strips  58 ,  60  defined by lines of weakness  46 ,  48 .  
         [0028]    The adhesive patterns preferably also include second adhesive pattern(s)  62 ,  64  comprised of one or more strips or segments for closing and adhering the intermediate along the top of the C-folded mailer. Thus, an illustrated embodiment, pressure seal cohesive  62  is provided adjacent the top edge of the second face of the first panel and on the first face of the third panel adjacent the second fold line  26 . It is to be noted that in the presently preferred embodiment the second adhesive patterns are sized and positioned so as to be disposed in a limited area adjacent the top edge  66  of the folded document/envelope  68  so that the adhesive will be removed when the top edge  66  of the envelope  68  is slitted by an automated slitter. In this regard, because slitters and similar devices remove only small amounts of material (typically {fraction (1/16)}″ to {fraction (3/32)}″ in height), the adhesive  62   64  is desirably placed with a high level of accuracy, within an area about ⅛″ from the respective edges of the panels so that the adhesive applied to the document during manufacture does not substantially extend more than the above-noted typical dimensions below the top edge  66  of the folded form. As an alternative to providing second adhesive areas  62 ,  64 , the top edge  66  of the mailer may be held closed and sealed using a tab or tabs  70  as schematically illustrated in FIG. 4, since this would still accomplish a desired result of freeing the contents defined by the third panel  32  when the document/envelope  68  is passed through a slitter or similar device  72 .  
         [0029]    Preferably, the adhesive  54 ,  56 ,  62 ,  64  for securing the intermediate in the C-fold mailer configuration is a substantially permanent adhesive that is defined by pressure seal adhesive or cohesive for sealing the mailer upon folding and the application of suitable pressure to the adhesive region. In the alternative, however, the adhesive may be a re-wettable adhesive, or a pressure sensitive adhesive covered by a release strip. Also, rather than continuous elements, the adhesive  54 ,  56 ,  62 ,  64  may be provided as discontinuous elements and/or in a pattern, shape or density other than that shown. Thus, the adhesive areas may take any configuration including dash lines, discontinuous dot configurations and the like. However, it is preferred that the amount and spacing of such adhesive material be at least sufficient to allow the mailer to be processed by U.S. Postal Service automated systems.  
         [0030]    As noted above, the intermediate also preferably includes security-screened areas  50 ,  52  formed on the second face  22  of those portions as the first and second panels  28 ,  30  that will form the interior of the outgoing envelope. The security screening may be provided by any conventional technique normally prior to the time that the intermediate is transported to the entity or system that will be printing the variable information, such as outgoing address indicia and remittance details.  
         [0031]    Although not shown, detachable tractor drive strips may be provided for the intermediate during processing. These strips are conventional for facilitating handling of the intermediate for printing or the like during manufacture of the mailer. These strips are typically provided where the intermediate is in continuous form so that the top and bottom edges  12 ,  14  are lines of weakness between the longitudinally adjacent intermediates. During normal processing, such strips, (not shown) are slit off at an appropriate stage to define the side edges  16 , 18 .  
         [0032]    In constructing the mailer, after the intermediate  10  is detached from the adjacent intermediate continuously printed therewith (if any) and after slitting of any tractor drive strips (if provided), the third panel  32  is die cut along lines  34 ,  36  as shown. The resultant intermediate is C-folded as illustrated in FIG. 3, (typically by conventional folding equipment) and is then run through a suitable sealing machine (typically conventional equipment, either heat sealing or pressure sealing) for activating the adhesive patterns  54 ,  56 ,  62 ,  64 . Typically the intermediate shown in FIGS. 1 and 2 has a length between top and bottom edges  12 , 14  of less than 12″. In the illustrated embodiment, the first and second panels each have a top to bottom (width) dimension of about 3¼″, whereas the third panel, as defined by die cutting or by the placement of the lines of weakness, has a length of about 3{fraction (1/16)}″. In the illustrated embodiment, the third panel is die cut to define a standard 6″ length check. It is to be understood that if the third panel is adapted to define a statement, receipt, or the like, the die cut length can be varied but is advantageously less than the space or length between lines of weakness  46  and  48 .  
         [0033]    When the outgoing addressee receives the mailer, the mailer  68  is then comprised of first, second and third plys or panels with the second or bottom face of the first panel  28  in face to face relation with the first or top face of the third panel  32  and the second or bottom face of the second panel  30  in face to face relation with the second or bottom face of the third panel  32 . The mailer can be easily opened, as illustrated in FIG. 4, by using automated slitter equipment  72 , to slit along the top edge  66  of the mailer. In the illustrated embodiment, the top face of the first panel  28  is preprinted with envelope slitter marks as at  74  and may include preprinted indicia  76  such as “ENVELOPE SLITTER MARK” so that the end user recognizes that the mailer may be opened using automated slitter equipment.  
         [0034]    Because the third panel  32  is shorter in length and width than the first and second panels  28 ,  30 , the third panel is free floating inside the mailer  68  except for its attachment to the second panel along line of weakness  26 . Once the mailer has been passed through a slitter  72 , however, the third panel  32  is severed adjacent the second line of weakness  26  so that the remainder  78  of the third panel is entirely free floating in the mailer and can be removed through the slit open top as illustrated in FIG. 5. When the mailer is slitted using automated slitter equipment  72  as shown in FIG. 4, it is unnecessary to remove the side strips  58 ,  60  of the envelope.  
         [0035]    In the event the mailer is received by an end user that does not use automated slitter equipment, the mailer may nevertheless be opened promptly in a conventional manner as illustrated in FIG. 6 by tearing along lines of weakness  46  and  48  and by disrupting the adhesive areas  62 ,  64  along the top edge  66  of the mailer  68  or disrupting the tabs  70 , if provided in lieu of adhesive with an index finger or letter opener. The resultant opened mailer is illustrated in FIG. 7 and the check or other remittance provided as the third panel  32  may be removed from the opened mailer by tearing along the line of weakness  26 .  
         [0036]    The intermediate and mailer according to the present invention has a number of advantageously results. A major benefit of the design is the ability to open the mailer using conventional slitter equipment  72 . A second advantage is the ability to automatically match up the contents with a secure envelope created from the same sheet of paper. Other materials may also be added to the mailer piece by nesting through the use of a equipment similar to a Moore PS-1 or LM-20 Model pressure seal system. Additional advantages include the ability to print variable information on the outgoing mail piece, such as multiple return addresses, individual account numbers, and the like and the ability to include USPS PostNet barcodes on the outgoing mail piece.  
         [0037]    The embodiment described above creates a single panel inside a carrier or letter by C-folding the intermediate. As an alternative to a C-folded mailer, the invention may be adapted to incorporation in a four panel, double V-fold mailer as illustrated in FIGS. 8-11. In this embodiment, several features incorporated in the first embodiment are again provided and the same are similar references are utilized each incremented by  100 , but are not described hereinbelow.  
         [0038]    An exemplary alternative intermediate for a mailer-type business form is shown generally by reference number  110  in FIGS. 8 and 9. It includes a quadrate sheet of substantially opaque paper having parallel top and bottom edges  112 , 114  and parallel first and second side edges  116 , 118 , respectively. The side edges are perpendicular to the top edge. First, second, and third fold lines  124 , 125 , 126  are provided parallel to the top and bottom edges for dividing the sheet into four panels. The first, second, and fourth panels  128 , 130 , 131  are substantially equal size. According to an exemplary embodiment of the invention, however, the fold lines  124 ,  125 , 126  are disposed and/or the bottom edge  114  of the intermediate is die cut so that the third panel  132  has a width, defined between the third fold line  126  and the bottom edge  114 , that is less the width of any of the first, second, and fourth panels  128 , 130 , 131 . The intermediate is die-cut during the manufacturing process, most preferably after printing and before folding, along lines  134 ,  136 , as shown in FIGS. 8 and 9 to truncate the length of the third panel.  
         [0039]    With reference to embodiment illustrated in FIGS. 8 and 9, the first panel  128  is disposed as the top panel of the form, the second panel  130  is disposed as the upper middle panel, the third panel  132  is disposed as the bottom panel and the fourth panel  131  is disposed as the lower middle panel of the form. Thus, in the illustrated embodiment, the fourth panel  131  is interposed between said second and third panels  130 ,  132 . Fold lines  124 ,  125 ,  126  may comprise lines of weakness such as perforation lines or die cut lines or may merely be scored or crease lines. The invention is not limited however to the described series and orientations of panels.  
         [0040]    The intermediate also includes an outgoing address area  138  on the first face of the first panel. The outgoing address area  38  is of a size and adapted to receive, e.g., a laser printed address or pre-printed address label. The outgoing address area can include indicia corners or other indicator such as a change in texture, tone or color of the paper to facilitate the determination of the proper location of the outgoing address. Such indicators, however, are not critical to the implementation of the invention. Human readable address indicia is ultimately provided in area  138  as, for example, it is passed through a printer. Other human or machine readable indicia may also be printed or pre-printed on the first face of the first panel, such as postal address bar coding (not shown), indicia  142  for postal stamp application and/or indicia  144  for the sender&#39;s return address. It is to be understood that since the first and second panels together define the out-going envelope, rather than providing the outgoing address, postal and return address indicia on the first face of the first panel, such indicia may be provided on the first face of the second panel  130 , upside down relative to the orientation provided in the illustrated embodiment on the first panel  128 , without departing from this invention.  
         [0041]    As illustrated, the fourth panel  131  may include remittance advice or other pre-printed or variably printed information.  
         [0042]    In the illustrated embodiment, the third panel  132  is configured as a negotiable instrument, such as a check, and thus advantageously includes human or machine readable indicia preprinted on the first and/or second face of the third panel and variably imaged indicia identifying, for example the payee and the amount paid. It is to be understood, however, that the bottom, separable panel need not be a check, but can be printed as an invoice, statement, receipt, or offer informational or commercial document.  
         [0043]    A first line of weakness  146  is formed in the first, second and fourth panels  128 ,  130 ,  131 , parallel to and spaced from the first side edge  116 . The first line of weakness defines a tear off strip  158  provided for readily opening one side of a mailer constructed by folding the intermediate about fold lines  124 , 125 , 126 . A second line of weakness  148  is further formed on the first and second panels parallel to and spaced from the second side edge  118 . The second line of weakness defines a tear off strip  160  providing for ready opening of the other side of the mailer constructed by folding the intermediate about fold lines  124 ,  125  and  126  as shown in FIGS. 10 and 11.  
         [0044]    The intermediate further comprises a first plurality of adhesive patterns  154 ,  155  provided along at least some of the edges of the panels for holding the first three panels together in the outgoing mailer configuration when the sheet is folded about fold lines  124 , 125 , 126  as illustrated in FIG. 10 or  11 .  
         [0045]    The adhesive patterns preferably also include second adhesive pattern(s)  163 ,  165  comprised of one or more strips or segments for closing and adhering the intermediate along the bottom of the folded mailer. Thus, an illustrated embodiment, pressure seal cohesive  163 ,  165  is provided adjacent the top edge of the face of the first panel and on the first face of the fourth panel adjacent the second fold line  125 . As an alternative to providing second adhesive areas  163 ,  165 , the bottom edge of the mailer may be held closed and sealed using a tab or tabs, since this would still accomplish a desired result of freeing the contents defined by the third panel  132  when the document/envelope is passed through a slitter or similar device.  
         [0046]    Preferably, the adhesive  154 ,  156 ,  163 ,  165  for securing the intermediate in the C-fold mailer configuration is a substantially permanent adhesive that is defined by pressure seal adhesive or cohesive for sealing the mailer upon folding and the application of suitable pressure to the adhesive region. In the alternative, however, the adhesive may be a re-wettable adhesive, or a pressure sensitive adhesive covered by a release strip. Also, rather than continuous elements, the adhesive may be provided as discontinuous elements and/or in a pattern, shape or density other than that shown. Thus, the adhesive areas may take any configuration including dash lines, discontinuous dot configurations and the like. However, it is preferred that the amount and spacing of such adhesive material be at least sufficient to allow the mailer to be processed by U.S. Postal Service automated systems.  
         [0047]    In constructing the mailer, after the intermediate  110  is detached from the adjacent intermediate continuously printed therewith (if any) and after slitting of any tractor drive strips (if provided), the third panel  132  is die cut along lines  134 ,  136  as shown. The resultant intermediate is double V-folded as illustrated in FIG. 10 or V-C folded as illustrated in FIG. 11, (typically by conventional folding equipment) and is then run through a suitable sealing machine (typically conventional equipment, either heat sealing or pressure sealing) for activating the adhesive patterns  154 ,  156 ,  163 ,  165 .  
         [0048]    When the outgoing addressee receives the mailer, the mailer, the mailer can be easily opened, using automated slitter equipment, to slit along the top edge  66  of the mailer. Because the third panel  132  is shorter in length and width than the first, second, and fourth panels  128 ,  130 ,  131 , the third panel is free floating inside the mailer except for its attachment to the fourth panel along line of weakness  126 . Once the mailer has been passed through a slitter, however, the third panel  132  is severed adjacent the second line of weakness  26  so that the remainder of the third panel is entirely free floating in the mailer and can be removed through the top of the slitted mailer. In the event the mailer is received by an end user that does not use automated slitter equipment, the mailer may nevertheless be opened promptly in a conventional manner.  
         [0049]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.