Abstract:
Embodiments of the present invention provide a folding mailer that can provide one or more of the following advantages: accommodate pictures or other printed material extending across multiple portions of the item, be folded into a minimal thickness for efficient mailing, be unfolded into a relatively large continuous display surface, and be folded and mailed without external packaging or adhesives that can mar or damage portions of the item when opened.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority as a continuation of U.S. provisional application 61/321,668, filed Apr. 7, 2010, which application is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to items suitable for mailing, and more specifically to items that can receive a large format image or collage of images, and then be folded for convenient mailing. 
       BACKGROUND OF THE INVENTION 
       [0003]    Printed items are used to share photos and information, for example in picture postcards, souvenir posters and photographs, etc. Various foldable items have been proposed to allow large format (larger than customary one page postcard) to be mailed within normal mailing size constraints. 
         [0004]    As an example, U.S. Pat. No. 3,141,549 discloses a foldable postal card. The disclosed postal card comprise a paper fold construction which provides a flip action with a portion of the fold is pulled out or otherwise moved by finger action. The patent asserts that conventional folding postal cards provide nothing to forcefully call attention to any particular portion of the card. A stated object of the patent is to provide a foldable postal card which provides a flip action so as to call attention to a particular portion of the card in a striking manner. The card opens along parallel fold lines, and has a crease that allows one portion of the card to be pulled out. In some embodiments, a tab engages a slot in the middle of a surface (after folding), covering and inhibiting the action of the flip action mechanism. 
         [0005]    As another example, U.S. Pat. No. 3,190,541 discloses a greeting card assembly that fold to provide a slotted compartment for holding a personal letter or the like. The assembly has a slot that allows access to a compartment formed by folding of the card. In some embodiments, flaps are provided which overlap and are glued to the rest of the card to seal the assembly. 
         [0006]    As another example, U.S. Pat. No. 4,780,975 discloses a self mailer that provides one or two separate framed pockets, formed of multiple layers of material that combine to provide a pocket for a separate photo with an open viewing area with a surrounding border. The mailer can be folded such that the viewing area(s) are on the outside faces of an easel formed by the mailer. The thickness of the photo frame portions requires that the sheet be cut in multiple display embodiments, as in  FIG. 14 . 
         [0007]    As another example, U.S. patent application 20030222128 discloses a picture postcard mailer with rigid frame and stand. A frame portion defines a viewing aperture and a pocket to retain a picture inserted into the pocket. A portion of the frame portion on a surface opposite the viewing aperture can partially separated from the frame portion and hinged outward to provide support to the frame portion allowing upright display of the picture. 
         [0008]    The art, however, cannot accommodate pictures or other printed material extending across multiple portions of the item, and cannot be folded into a minimal thickness for efficient mailing, and cannot be unfolded into a relatively large continuous display surface, and cannot be folded and mailed without external packaging or adhesives that can mar or damage at least portions of the item when opened. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The accompanying drawings, which are incorporated in and form part of the specification, illustrate the present invention and, together with the description, describe the invention. In the drawings, like elements are referred to by like numbers.  FIG. 1(   a,b,c,d,e ) comprise illustrations of an example mailer according to the present invention at various stages of folding. 
           [0010]      FIG. 2(   a,b,c,d,e ) comprise illustrations of an example mailer like that in  FIG. 1  with images printed thereon. 
           [0011]      FIG. 3  is an illustration of an example mailer according to the present invention with curved edges. 
           [0012]      FIG. 4  is an illustration of an example embodiment according to the present invention with a variation of folding pattern and tab/slot relationship. 
           [0013]      FIG. 5  is an illustration of an example embodiment according to the present invention with an additional fold relative to an embodiment such as in  FIG. 1 . 
           [0014]      FIG. 6  is an illustration of an example embodiment like that in  FIG. 5  except with a variation of folding pattern and tab/slot relationship. 
           [0015]      FIG. 7  is an illustration of an example embodiment where the item has two nonparallel sides. 
           [0016]      FIG. 8(   a,b,c,d ) is an illustration of an example embodiment according to the present invention, having a roughly pennant shape and showing several stages of folding. 
           [0017]      FIG. 9(   a,b,c,d,e ) is an illustration of an example embodiment according to the present invention, having folds that define several roughly triangular portions and showing several stages of folding. 
           [0018]      FIG. 10  is an illustration of an example embodiment according to the present invention having a roughly circular shape foldable along radial lines. 
           [0019]      FIG. 11  is an illustration of an example embodiment according to the present invention formed from a single rectangular sheet. 
           [0020]      FIG. 12  is an illustration of an example embodiment of the present invention suitable for continuous feed production. 
           [0021]      FIG. 13  is an illustration of an example embodiment allowing two triangular mailers to be produced from a single rectangular sheet. 
           [0022]      FIG. 14  and  FIG. 15  comprise illustrations of an example embodiment illustrating alternative tab configurations. 
           [0023]      FIG. 16  is an illustration of an example embodiment illustrating alternative tab configurations. 
           [0024]      FIG. 17  comprises illustrations of various alternative tab configurations. 
           [0025]      FIG. 18  is a photograph of an example mailer embodiment according to the present invention. 
           [0026]      FIG. 19  is a photograph of an example mailer embodiment according to the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    The present invention is described in terms of a mailer, where a “mailer” refers to an item that can be folded or otherwise configured to a shape and size suitable for mailing through postal services or other flat item delivery services. As used herein, “mailer” also includes items that can be folded for more convenient handling, even if the final size, shape, thickness, weight, or material is not suitable for delivery by postal services. Mailers according to the present invention can have images incorporated into them, where an “image” includes any graphical information, including without limitation photographs, drawings, text, collages of photographs, and combinations of the preceding. Images can be incorporated into mailers in various manners known to those skilled in the art, including as examples by various mass production printing methods, individual item printing methods, application by hand (such as handwriting or drawing), and combinations thereof. Mailers are described herein as having prefold lines, where a “prefold line” includes any element that facilitates folding of the sheet along that line, as examples including indications such as dotted lines printed on the sheet, scorings of the sheet, perforations in the sheet, pressed lines into the sheet. Scoring can make folding easy to accomplish reliably on the desired line, and does not generally interfere with an image placed on the sheet. Perforations can make folding easy, and can make the sheet easy to separate along the prefold lines (desirable if the application desires to separate the sheet), but can interfere with an image that crosses the perforation line. Fold indications printed on the sheet can be easy to place, but can lead to inaccurate folding and in some instances can interfere with images that cross such fold indications. Lines pressed into the sheet can function similarly to scoring, but if the sheet is not cut then pressed lines can pose less interference with images that cross the prefold lines, and can avoid weakening the sheet. Sheets can also have other features such as perforations, for example if it is desired to separate multiple images (e.g., if one mailer has several detachable coupons printed on it). 
         [0028]      FIG. 1(   a,b,c,d,e ) comprise illustrations of an example mailer according to the present invention at various stages of folding. In  FIG. 1   a , a single sheet  11  of material is depicted. The material can be a preprinted sheet, or a material suitable for receiving an image on one or both sides. As examples, paper of various weights, matte or glossy finishes, posterboard, card stock, plastic sheets can all be suitable for use with the present invention. The single sheet  11  is of generally rectangular shape, which includes squares and rectangles of various aspect ratios. A “generally rectangular shape” is also intended to encompass shapes such as in certain of the other embodiments described herein, including those with non-straight sides but where corners can be aligned after folding along lines such as those described in connection with the relevant figures. The generally rectangular shape has a tab  12  extending from one edge, and extending along less than one half of that edge. A slot  13  is cut into the sheet spaced from an edge of the sheet  11  such that the slot  13  will be parallel to the tab  12  and will mate with the tab edge after folding. 
         [0029]    The sheet  11  has three prefold lines: a tab prefold line  14  between the tab and the rest of the sheet, a second prefold line  16  parallel to the tab edge and approximately halfway between tab edge and the opposing edge, and a third prefold line  15  perpendicular to the second prefold line  16  and approximately bisecting the second prefold line  16 . The various prefold lines can be accomplished in different manners; as an example, the tab prefold line  14  can be perforated (to facilitate folding, and later separation, of the tab), while the second and third prefold lines  15 ,  16  can be scored or pressed. 
         [0030]    In  FIG. 1   a  the sheet is flat and unfolded. One or more images can be placed on one side of the sheet, or one both sides as described later. The sheet can then be folded along prefold line  15 .  FIG. 1   b  shows the sheet after folding the lower portion in  FIG. 1   a  up (out of the page) along prefold line  15  to meet the upper portion in  FIG. 1   a . The slot  13  is obscured by the portion of the sheet folded up.  FIG. 1   c  shows the other side of the same folding: the slot  13  is visible, as is the tab prefold line  14 . 
         [0031]    The sheet as shown in  FIG. 1   b  can be folded along prefold line  16 , with the right portion being folded over to the left (out of the page) to produce the image of  FIG. 1   d . The slot  13  is now near the tab.  12 , and the resulting mailer has a rectangular shape. The tab  12  can then be folded along tab prefold line  14  (obscured in  FIG. 1   d  by the portions of the sheet that have been folded) and tucked into the slot  13 , securing the folded mailer against unintended unfolding. The use of a tab and slot closure can reduce or eliminate the need for adhesive fastening. Adhesive fastening can complicate opening, can make reuse difficult, and can interfere with images that might be in the region of adhesive attachment. 
         [0032]      FIG. 2(   a,b,c,d,e ) comprise an illustration of an example mailer like that in  FIG. 1  with images printed thereon. In  FIG. 2   a , the surface of the sheet  21  that is inside after folding is shown with a photo of a baby. The photo extends over the surface of the sheet, in particular across the prefold lines  25 ,  26 . The sheet has a tab  22  and tab prefold  24  and slot  23 , similar to those described in relation to  FIG. 1 . The opposite side of the sheet  21  is shown in  FIG. 2   b . This side has different printings on each of the four quadrants formed by prefold lines  25 ,  26 . After a first folding along prefold line  25 , the mailer appears as in  FIG. 2   c . An image of a mother and child and an image of a wrapped present are visible on the quadrants that will be inside after the next fold. An announcement text is visible on one quadrant that will be visible after the next folding. Address and postage can be placed on the fourth quadrant, also visible after the last folding, as in  FIG. 2   d . Each side of the mailer that is visible after folding and after insertion of the tab into the slot is shown in  FIG. 2   e.    
         [0033]      FIG. 3  is an illustration of another example embodiment. The sheet  31  has curved edges at the top and bottom and a tab  32 . The opposing corners line up when folded along prefold lines  35 ,  36 . The shape shown in  FIG. 3  is intended to fit within the scope of “generally rectangular” as described above. The surface of the sheet shown has several photos; as an example these can be sports photos and the overall mailer be used as memorabilia of a sports team, player, season, or event such as a championship. 
         [0034]      FIG. 4  is an illustration of another example embodiment. The sheet  41  has a generally rectangular shape, with a tab  42 . Slot  43  is along the same edge as tab  42 . In use, the mailer would first be folded along prefold line  46 , and then along prefold line  45 , such that when fully folded slot  43  allows engagement of tab  42 . As an example of the embodiment in use, the sheet in  FIG. 4  has an image of a group, such as a family gathering, a sports team, or a business staff. 
         [0035]      FIG. 5  is an illustration of another example embodiment. The sheet  51  has a generally rectangular shape, with a tab  52 . A fourth prefold line  57  is roughly parallel to prefold line  56 , and together prefold lines  56 ,  57  divide the sheet into thirds. In use, the sheet  51  is first folded along prefold line  55 , then along prefold line  57 , then along prefold line  56 , leaving slot  53  positioned to engage tab  52 . A single image can extend across the prefold lines, as shown in the figure, or multiple images can be placed on the sheet  51 . 
         [0036]      FIG. 6  is an illustration of another example embodiment. The sheet  61  has a generally rectangular shape, with a tab  62  and prefold lines  64 ,  65 ,  66 ,  67 . In use, the sheet  61  is first folded along prefold line  67 , then along prefold line  66 , then along prefold line  65 , leaving slot  63  positioned to engage tab  62 . 
         [0037]    Additional prefold lines can be employed to allow even larger sheets to be folded into the desired size, for example to comply with mailing limits. Each fold, though, increases the thickness of the folded mailer, so too many folds can lead to excessive mailer thickness. 
         [0038]      FIG. 7  is an illustration of another example embodiment. A sheet has a trapezoidal shape, with prefold lines roughly bisecting the sides. After folding along the prefold lines, a slot is positioned to engage a tab. The fully folded mailer in this example is not rectangular, which can add interest but can also complicate some mailing operations or require additional postage. 
         [0039]      FIG. 8(   a,b,c,d ) is an illustration of another example embodiment. A sheet  81  has a roughly triangular shape, such as a common pennant. The sheet has a slot  83 , and prefold lines  84 ,  85 , and  86 . In use, the sheet in  FIG. 8   a  is folded along prefold lines  85  to produce the mailer shown in  FIG. 8   b . The sheet is then folded along prefold line  86  to produce the mailer shown in  FIG. 8   c  (turned over from the illustration in  FIG. 8   b ). The point of the triangle is then folded along prefold line  84  and tucked into slot  83 , producing a rectangular mailer as shown in  FIG. 8   d.    
         [0040]      FIG. 9(   a,b,c,d,e ) is an illustration of another example embodiment. A sheet is roughly semicircular (with outer straight chords, as shown, or could be with outer edge curved as with a true semicircle). In use, the sheet is first folded along prefold line  94 , producing the view as in  FIG. 9   b . Then it is folded along prefold line  95 , producing the view as in  FIG. 9   c . Then it is folded along prefold line  96 , producing the view as in  FIG. 9   d . Then then tab is folded and inserted in the slot, producing the folded mailer as in  FIG. 9   e.    
         [0041]      FIG. 10  is an illustration of another example embodiment. A sheet is roughly circular (with outer edge curved, as shown, or could be with outer edge comprised of straight chords), and separated into segments by a plurality of prefold lines. One segment is removed to provide room for a tab. In use, the sheet if successively folded along prefold lines in a similar manner as the example of  FIG. 9 . After the last fold, the tab is folded and engaged with the slot to yield a finished mailer. Those skilled in the art appreciate that other variations of the shapes described herein are possible and within the scope of the present invention. 
         [0042]      FIG. 11  is an illustration of another example embodiment. A rectangular sheet has perforations or cut guides that allow easy separation of the waste portions  112  from the rest of the sheet, producing a mailer sheet similar to that described in  FIG. 1 . The waste portions can be removed after printing in a standard printer, allowing the completely rectangular sheet to be printed in accord with many conventional printer configurations that assume rectangular sheets. Similar perforations or cut guides can be used to produce sheets such as those in the other figures, as well. 
         [0043]      FIG. 12  is an illustration of an example embodiment suitable for continuous feed production. A continuous sheet has prefold lines  123  placed thereon. The sheet has perforations, cut guides, or is die cut post printing along cut lines  121 , to form the desired slot as well as to separate the continuous sheet into separate mailers. The overlapping tabs provide for relatively small waste. 
         [0044]      FIG. 13  is an illustration of an example embodiment allowing two triangular mailers to be produced from a single rectangular sheet. The rectangular sheet can be separated along a diagonal of the rectangle. Each triangular half can then be folded along prefold lines shown, and the tip of the triangle inserted into a slot to secure the folded mailer. The tip can be tapered slightly as shown in the lower triangle to better fit the slot. The prefold lines can be at a non-perpendicular angle (exaggerated in the upper triangle in the figure) to result in the tip engaging the slot at a small distance from the edge. 
         [0045]      FIG. 14  and  FIG. 15  comprise illustrations of an example embodiment illustrating alternate tab configurations. Slots are placed at an angle to the edges of a sheet. A tab has a rectangular shape with relieved edges for at least a part of the length of the tab (as in  FIG. 14 ) or the full length of the tab (as in  FIG. 15 ). After folding, the corners of the tab can be inserted into the angled slots, securing the folded mailer. 
         [0046]      FIG. 16  is an illustration of an example embodiment illustrating an alternative tab configuration. Tabs comprising a semicircular or other convex shape are formed in a portion of a sheet. The tabs can be protrusions from the sheet as shown in the lower tab, or can be cut so as to remain attached to the sheet at a base with a convex portion hinging away from the sheet. The tabs then can engage corresponding slots in another portion of the sheet.  FIG. 17  comprises illustrations of alternative tab configurations, with each drawing showing two variations of a selected tab feature shape. Tab features with rounded corners can reduce snagging on automated handling equipment. Tab features that comprise slots cut into a sheet, without changing an overall rectangular shape of the sheet, can facilitate handling by conventional sheet handling equipment. 
         [0047]      FIG. 18  is a photograph of an example mailer embodiment according to the present invention. The sheet is similar in configuration to that illustrated in  FIG. 1 , with the photograph showing prefold lines, tab, and slot in an unfolded configuration (top) and after folding and tab insertion (bottom). 
         [0048]      FIG. 19  is a photograph of an example mailer embodiment according to the present invention. The sheet is similar in configuration to that illustrated in  FIG. 1 , with the photograph showing prefold lines, tab, and slot in various stages of folding. In the top portion of the figure, from left: address portion of mailer completely folded and ready to mail; mailer after one folding, showing half-page image that will be concealed after second folding; mailer unfolded, showing full-page image that will be concealed within the folded mailer; back side of mailer after complete folding. In the bottom portion of the figure, from left to right: unfolded mailer, showing address portion, back side, and half-page image; mailer after unfolding and after removal of the tab, showing full-page image suitable for display. 
         [0049]    The present invention has been described in view of various example embodiments. It will be understood that the above description is merely illustrative of the applications of the principles of the present invention, the scope of which is to be determined by the claims viewed in light of the specification. Other variants and modifications of the invention will be apparent to those of skill in the art.