Abstract:
A tri-fold protective mailer for a stress-sensitive article. The protective mailer comprises a three-section, substantially-rectangular panel having a pocket on one outermost section for securing the stress-sensitive article. When the mailer is folded, the article is captured between the overlapping sections of the panel such that the stress-sensitive article is inaccessible from the exterior of the mailer. The pocket is positioned and configured such that the mailer can be handled by automated handling equipment without a significant risk of damage to the stress-sensitive article.

Description:
[0001]    This invention relates to mailers and, in particular, to tri-fold mailers which are suitable for securing and protecting mailpieces, such as stress-sensitive articles, for safe handling by automated handling equipment.  
         BACKGROUND OF THE INVENTION  
         [0002]    The United States Postal Service utilizes high-speed automated handling equipment for sorting the large volumes of mail that it handles daily. To that end, the automated handling equipment utilizes pairs of vertical moving belts arranged in a network to grip and serially transport mailpieces. The moving belts convey the mailpieces at a linear velocity approaching 500 to 600 feet per minute. Each mailpiece is oriented in a vertical plane such that a three (3) inch edge portion of the mailpiece is gripped between the moving belts. A sensor/translator is provided adjacent to the moving belts for identifying a destination post office for each mailpiece. Mailpieces are sorted according to the destination post office and routed by the network of moving belts into assorted collection bins. Changes in direction of transported mail in automated handling equipment are accommodated by providing a drum over which the moving belts are trained at the point where the direction change is to occur. For example, if the mailpiece is moving linearly in a horizontal direction and it is desired to effect a directional change to a different horizontal direction, a drum mounted for rotation about a vertical axis is placed at the change-of-direction point in the path of travel of the opposed belts between which the mailpiece is gripped for transport. As the belts move about the rotating drum, the mailpiece travels through a curved path conforming to the drum periphery and emerges traveling between the moving belts in a new horizontal direction.  
           [0003]    Conventional mailers are available for packaging breakable, frangible or stress-sensitive articles, such as compact disks or mini-compact disks, in a manner suited for handling by the automated handling equipment. Automation-compatible mailpieces must comply with postal regulations such as size requirements and address positioning while protecting the stress-sensitive article from damage during sorting by the automated handling equipment. Moreover, postal regulations require the mailer to be flexible enough to be bent and routed about the circumference of a cylindrical drum having an eleven (11) inch diameter and a height of about three (3) inches of the type used in automated handling systems at locations where directional changes occur in the travel path of the belts.  
           [0004]    Stress-sensitive articles packaged in conventional mailers have a significant risk of breakage or damage as the mailer is bent about the circumference of the cylindrical drum. As the mailer is conveyed about the exterior of the drum, the stress-sensitive article must curve or bow and will experience a state of tension due to the flexure that can damage or even break the article. Moreover, conventional mailers position the stress-sensitive article such that the moving belts may apply a significant contact pressure to the article capable of damaging the surface of the stress-sensitive article so as to, for example, corrupt the information encoded thereon. Thus, because of these and other significant shortcomings, conventional mailers do not adequately safeguard stress-sensitive articles for handling by automated handling equipment used by the United States Postal Service.  
           [0005]    Accordingly, there is a need for a mailer for a stress-sensitive article that can be handled by automated handling equipment and that fully complies with postal regulations while protecting the stress-sensitive article from damage during transit and sorting.  
         SUMMARY OF THE INVENTION  
         [0006]    A primary objective of the present invention is to provide a mailer for a stress-sensitive article such that the mailer can be bent and transported about the circumference of the cylindrical drums used in automated handling equipment without damaging the article. A further objective of the present invention is to provide a mailer for a stress-sensitive article that positions the article such that the belts of the automated handling equipment do not contact the area of the mailer containing the article. A particular objective of the invention is to provide a mailer for a stress-sensitive article that can ensure damage-free handling by automated handling equipment of the postal service while securing the article during transit from a sender to a recipient.  
           [0007]    According to the principles of the present invention, a mailer is provided having a substantially rectangular first panel with a pair of transversely-oriented free ends and a first and a second transverse fold line. The first and second fold lines have a spaced relationship between the free ends of the first panel so as to divide the first panel into a first and a second outer section positioned longitudinally on opposite sides of a middle section when the mailer is in an unfolded state. A second panel is attached to the first outer section of the first panel. A pocket is collectively defined between the first and second panels and is dimensioned to receive the stress-sensitive article therein. The pocket has an opening facing the first transverse fold line for insertion and removal of the article. To define a folded state for securing the stress-sensitive article, the first outer section is folded at the second transverse fold line over the middle section to sandwich the second panel therebetween. The second outer section is folded over the middle section with the first outer section and the second panel located therebetween for securing the stress-sensitive article such that the article is inaccessible from the exterior of the mailer.  
           [0008]    These and other objectives and advantages of the present invention will be more readily apparent from the following detailed description. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    [0009]FIG. 1 is a perspective view of one embodiment of the mailer of the present invention in an unfolded state;  
         [0010]    [0010]FIG. 2 is a perspective similar to FIG. 1 illustrating the mailer of the present invention in a folded state;  
         [0011]    [0011]FIG. 2A is a cross-section taken generally along line  2 A- 2 A in FIG. 2;  
         [0012]    [0012]FIG. 3 is a schematic side view illustrating the mailer of the present invention being handled by automated handling equipment;  
         [0013]    [0013]FIG. 4 is a schematic top view similar to FIG. 3, illustrating the handling of the mailer of the present invention by the automated handling equipment; and  
         [0014]    [0014]FIG. 5 is a partial perspective view, similar to FIG. 1, of one embodiment of the mailer of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0015]    With reference to FIGS. 1 and 2, a mailer  10  according to the present invention comprises a first panel  12  adapted to be folded or bent over a second panel  14  and a third panel  16  also adapted to be folded over the second panel  14 . The first and second panels  12 ,  14  are hingeably or foldably joined at a fold line  22  and the second and third panels  14 ,  16  are likewise hingeably or foldably joined at a fold line  24 . Although fold lines  22 ,  24  need not be scored or otherwise defined, fold lines  22 ,  24  may be scored or perforated to facilitate manual folding. The mailer  10  has an open or unfolded position, shown in FIG. 1, wherein the panels  12 - 16  are adjacent to each other in substantially the same plane and a closed or folded position, shown in FIG. 2, wherein the panels  12 - 16  are in substantially parallel planes atop each other or stacked in substantially parallel planes. The fold lines  22 ,  24  are substantially parallel to or transverse to the longest or major dimension of mailer  10  and have a spaced relationship to divide the mailer  10  into the trio of panels  12 - 16 .  
         [0016]    The mailer  10  includes a pouch or pocket  18  that is configured to hold and protect a stress-sensitive article  20 . The pocket  18  is collectively formed as a space between a fourth panel  21  and the third panel  16  by attached portions  56  and the false bottom  52  provided by adhesive  50  (FIG. 2A). The pocket  18  includes an opening  23  oriented to face substantially toward the fold line  24  and dimensioned to receive the stress-sensitive article  20  therethrough for positioning within pocket  18 . The third and fourth panels  16 ,  21  are hingeably joined at a fold line  25 . It is understood by those of ordinary skill in the art that the fourth panel  21  is not limited to being integrally joined to third panel  16  in a hingeable fashion at the fold line  25  and, in certain embodiments, the fourth panel  21  can comprise an independent, separate panel interconnected by adhesive  50  (FIG. 2A) and attached portions  56  to panels  12 - 16  to create pocket  18 .  
         [0017]    The paper stock or cardboard forming panels  12 - 16  and  21  is stiff enough to withstand handling in automated mail handling equipment without significant damage so as to protect the stress-sensitive article  20  that will be enclosed in the mailer  10 , yet lightweight for purposes of manufacturability and to minimize mailing costs. The mailer  10  is constructed to substantially comply with United States Postal Service regulations governing automation-compatible mailpieces. To that end, the mailer  10  must have a height between 6.125 inches and 3.5 inches and a length between 5 inches and 11.5 inches, wherein length is the dimension parallel to the address when that address is read and the height is the dimension perpendicular to the length. Mailer  10  must have a ratio of length to height, or aspect ratio, between 1.3 and 2.5. Panels  12 - 16  are larger than the pocket  18  so that the mailer  10  can absorb corner denting, thereby protecting the stress-sensitive article  20  inside pocket  18 . Further, postal regulations require that the mailer  10  and its contents, stress-sensitive article  20 , bend easily when transported about an 11 -inch diameter cylindrical drum  60 , as shown in FIGS. 3 and 4.  
         [0018]    With continued reference to FIGS. 1 and 2, the first panel  12  has an inner face  26 , an outer face  27 , a free end or first transverse end  28 , a second transverse end  29  and a pair of lateral ends  30 . Similarly, the second panel  14  has an inner face  32 , an outer face  33  (FIG. 3), a first transverse end  34 , a second transverse end  35  and a pair of lateral ends  36 . The third panel  16  has an inner face  38 , an outer face  39  (FIG. 2A), a free end or first transverse end  40 , a second transverse end  41  and a pair of lateral ends  42 . The fold line  22  is defined by the juncture of the second transverse end  29  of the first panel  12  and the first transverse end  34  of the second panel  14 . Similarly, the fold line  24  is defined by the juncture of the second transverse end  41  of the third panel  16  and the second transverse end  35  of the second panel  14 . The inner faces  26 ,  32  may carry a message, advertising material or other printed indicia  43 . Although not shown, faces  27 ,  33 ,  39 , and  45  may also carry printed indicia, similar to the printed indicia  43  on inner faces  26 ,  32  without departing from the spirit and scope of the present invention. In certain embodiments, panels  12 - 16  are substantially rectangular, as illustrated in FIGS. 1 and 2, but it is understood that the present invention is not so limited.  
         [0019]    The fourth panel  21  has an inner face  44  (FIG. 2A), an outer face  45 , a first transverse end  46 , a second transverse or free end  47 , and a pair of lateral ends  48 . Referring to FIGS. 2 and 2A, an adhesive  50 , such as an adhesive strip or plural dots of adhesive, is provided between the first transverse end  47  of fourth panel  21  and the first transverse end  40  of the third panel  16 . The adhesive  50  is aligned transversely with an orientation that is substantially parallel to transverse ends  40 ,  47 . The adhesive  50  defines a false bottom  52  between the third and fourth panels  16 ,  21  which limits the depth of the pocket  18  accessible to the stress-sensitive article  20 . The width of the false bottom  52  controls a surface area or top edge  54  of the article  20  that is exposed above the first transverse end  46 . The depth of the pocket  18  is measured perpendicular to the first transverse end  40  of the third panel  16  or, equivalently, perpendicular to the fold line  25 , from the opening  23  to the false bottom  52 . The inner face  44  of fourth panel  21  is attached, such as by an adhesive (not shown but similar to adhesive  50 ), on opposite sides of pocket  18  to the inner face  38  of third panel  16  to create a pair of attached portions  56 . The attached portions  56  are generally rectangular and define a pair of lateral edges or inner peripheral edges  57 . The linear separation between the inner peripheral edges  57  defines the lateral dimension of the pocket  18 .  
         [0020]    The dimensions of the pocket  18  are predetermined to accommodate the dimensions of the stress-sensitive article  20  and, if the article  20  is a magnetic or optical memory storage medium, to protect the vulnerable storage area of the article  20  from damage. The pocket  18  has a lateral dimension or width that is slightly greater than a first dimension of the stress-sensitive article  20  and a depth defined by the false bottom  52  that is slightly less than a second dimension of the article  20 . When the stress-sensitive article  20  is fully received in pocket  18 , the false bottom  52  permits the top edge  54  of the article  20  to be visible when the mailer  10  is in an unfolded state. Typically, the false bottom  52  of pocket  18  is defined such that a linear dimension, measured perpendicular to the fold line  24 , of about 0.25 inches to about 0.5 inches of the top edge  54  is visible. However, the extent of the false bottom  52  is chosen to ensure that the nearest edge of the transport belts  58  (FIGS. 3 and 4) of the postal handling equipment do not contact any portion of the article  20  and defines the separation between the article  20  and the portion of mailer  10  gripped by the transport belts  58  (FIGS. 3 and 4). It is apparent that the false bottom  52  can be omitted in certain embodiments of mailer  10  without departing from the spirit and scope of the present invention so that the stress-sensitive article  20  abuts, or nearly abuts, the fold line  25 . When the mailer  10  is in a folded state, the pocket  18  and the article  20  are substantially inaccessible from the exterior of the mailer  10  without unsealing and unfolding the mailer  10 . In certain embodiments, it is understood by those of ordinary skill in the art that the mailer  10  may comprise a plurality of pockets  18  defined between the third and fourth panels  16 ,  21  as constrained by the transverse dimension of panels  16 ,  21  and the requisite transverse dimension of each of the plurality of pockets  18 .  
         [0021]    Because the top edge  54  of the stress-sensitive article  20  is exposed when the mailer  10  is unfolded, a recipient can readily determine whether or not the mailer  10  contains an article  20  without looking inside the pocket  18 . Moreover, any printed matter on the exposed top edge  54  of the stress-sensitive article  20  can be readily viewed without withdrawing the article  20  from pocket  18 . When the mailer  10  is in the folded state, the exposed portion of the stress-sensitive article  20  remains protected since article  20  is located in a secure position between the inner faces  32  and  38  of panels  14  and  16 , respectively. When the mailer  10  is in the unfolded state, the recipient can readily grasp the exposed top edge  54  of stress-sensitive article  20  for slidably removing article  20  from the pocket  18 .  
         [0022]    Exemplary stress-sensitive articles  20  include frangible or breakable articles, such as articles formed of a plastic, and more specifically, frangible articles such as storage media containing information. Common storage media include disc-shaped compact disks or mini-compact disks having at least one information-bearing surface. A typical mini-compact disk, for example, has a maximum linear dimension of less than about 3.5 inches.  
         [0023]    By way of example and not by way of limitation, the panels  12 - 16  may have a width of about 6 inches and a length of about 9 inches, with the pocket  18  dimensioned to contain a 2.4 inch by 3.1 inch mini-compact disk. The mini-compact disk is oriented with the shorter side generally aligned parallel to the folds of the panels  12 - 16  to provide a clearance of about 0.35 inches between the exposed top edge  54  and the nearest edge of the 3-inch wide transport belts  58  and the cylindrical drums  60  (FIGS. 3 and 4) of the automated handling equipment used to grip and transport the mailer  10 . The false bottom  52  has a depth such that the exposed top edge  54  of the mini-compact disk, visible when the panels  12 - 16  are unfolded, has a linear dimension of about 0.25 inches.  
         [0024]    With reference to FIG. 5 and according to one embodiment of the present invention, the first transverse end  46  of the fourth panel  21  may further include a notch  59  that permits the stress-sensitive article  20  to sit deeper within the pocket  18  while still exposing a significant portion of top edge  54 . In this embodiment, the engagement produced by the adhesive  50  (FIG. 2A) can be reduced in width to reduce the depth of the false bottom  52  or the adhesive  50  may even be eliminated so that the mailer  10  no longer includes a false bottom  52 . In the latter instance, a portion of the stress-sensitive article  20  in pocket  18  can abut or nearly abut the fold line  25 .  
         [0025]    [0025]FIGS. 3 and 4 schematically illustrate the handling of the mailpieces, such as mailer  10 , by conventional automated handling equipment comprising moving belts, such as transport belt  58 , and rotating drums, such as cylindrical drum  60 . The cylindrical drum  60  is used to change the direction of motion of the transport belts  58  and, thereby, to redirect the travel path of mailpieces, such as mailer  10 , gripped between the transport belts  58 . In such conventional automated handling equipment, transport belt  58  has a width of about 3 inches and the cylindrical drum  60  has a diameter of about 11 inches and a width of about 3 inches. Typically, a pair of transport belts  58  grasp a 3-inch wide height of the opposed parallel faces of each mailpiece, such as mailer  10 , and transport the mailer  10  along a travel path for a purpose such as sorting. The transport belts  58  are wound about and driven by the cylindrical drums  60  such that the mailer  10  must traverse a curved path about the circumference of cylindrical drum  60  in that portion of the travel path.  
         [0026]    With reference to FIG. 3, a return address  62 , a destination address  64 , postage indicia  66 , and a bar code  68  are typically provided on the outer face  33  of second panel  14 . The destination address  64  is printed such that the address is parallel to the longest dimension or length of mailer  10 . Mailpieces, such as mailer  10 , are usually oriented by postal handling equipment such that the destination address  64  of each mailpiece faces a consistent direction and with a consistent vertical orientation. Specifically, the longest dimension or length of the mailer  10  is aligned parallel to the direction of motion, indicated generally by arrow  70 . As a result, the bar code  68  is positioned such so that optical readers can be reliably positioned to sense the information encoded in bar code  68  for sorting the mailer  10  according to the destination address  64 . The orientation of mailer  10  between transport belts  58  ascribes a bottom edge  71  to mailer  10 , for purposes of reference only. According to the present invention, the stress-sensitive article  20  within the pocket  18  of mailer  10  is always positioned, relative to the bottom edge  71 , above the vertical extent of the transport belts  58  so that neither of the transport belts  58  can contact the portion of mailer  10  directly overlying the article  20 . Thus, the pocket  18  is configured such that the nearest portion of the exposed top edge  54  of the stress-sensitive article  20  is disposed at least  3  inches distant vertically from the bottom edge  71  of mailer  10 .  
         [0027]    With reference to FIGS. 3 and 4, mailer  10  is bent about the exterior of cylindrical drum  60  to change the direction of the travel path of mailpieces, such as for stacking the mailer  10 , along with other mailpieces, in a bin or receiver  72 . In the vicinity of the cylindrical drum  60 , the mailer  10  is constrained between transport belt  58  and a curved guide rail  74  and subsequently follows a curved path about the outer circumference of the cylindrical drum  60 . According to the present invention, the pocket  18  is positioned relative to the bottom edge  71  of mailer  10  such that the nearest portion of the stress-sensitive article  20  is always above and out of contact with the 3-inch vertical extent of the exterior surface of the drum  60 . Because the flexing of the mailer  10  near the pocket  18  is significantly reduced, the risk of damaging or breaking the stress-sensitive article  20  is significantly reduced when the mailer  10  moves in a curved path about the outer circumference of the cylindrical drum  60 .  
         [0028]    In use, the stress-sensitive article  20  is positioned through the opening  23  into pocket  18 . The third and fourth panels panel  16 ,  21  are folded at the fold line  24  to extend over the inner face  32  of the second panel  14  such that the stress sensitive article  20  and fourth panel  21  are sandwiched between the second and third panels  14 ,  16 . The first panel  12  is folded at the fold line  22  to extend over the outer face  39  of the third panel  16  and an exposed portion of the inner face  32  of the second panel  14  to establish a folded or closed state. In the folded state, the stress sensitive article  20  and the third and fourth panels  16 ,  21  are sandwiched between the second and third panels  14 ,  16  and the stress-sensitive article  20  is inaccessible from the exterior of the mailer  10 . A sealing member (not shown), such as an adhesive or a tape, is used to adhere the third panel  16  to the second panel  14  for sealing the mailer  10 . When the mailer  10  is in a folded state, the stress-sensitive article  20  is protected from damage and the article  20  is secured from becoming dislodged. The sender addresses the mailer  10  with at least the destination address  64  by any conventional means, such as typing or printing, and attaches the postage indicia  66 . The mailer  10 , in a closed state and sealed, is routed from the sender to the destination address  64  via the postal service, which typically utilizes automated handling equipment for sorting the mailer  10  according to the destination address  64 . The recipient opens the mailer  10  by compromising the sealing member and unfolding the panels  12 - 16  to the unfolded or open state. After unfolding, the printed indicia  43  carried by the inner faces  26  and  32  of panels  12 ,  14  will be visible to the recipient and the stress-sensitive article  20  will be exposed for ready identification and removal by the recipient.  
         [0029]    While the present invention has been illustrated by the description of embodiments example thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, the panel  21  may incorporate a window formed of a transparent material to accommodate viewing of the stress-sensitive article  20  in the pocket  18 . The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of applicant&#39;s general inventive concept.