Patent Publication Number: US-9850031-B2

Title: Simulated commercial envelopes and methods of making the same

Description:
RELATED APPLICATION 
     This patent arises from a continuation of U.S. patent application Ser. No. 12/163,177, filed Jun. 27, 2008, which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates generally to envelopes and more particularly, to simulated commercial envelopes and methods of making the same. 
     BACKGROUND OF RELATED ART 
     Mass produced integrated mailing envelopes are typically formed from webs of paper stock moving through inline presses. The inline presses create mail kits by integrating the envelope and internal components all in one print finishing process. For instance, a plurality of interconnected envelope blanks are formed from a web of paper. The integrated envelope is formed by sequentially applying adhesive to the edge and sides of the bottom flap and plow folding the flap over the main body. The top flap is then plow folded over both the main body and the bottom flap to seal the envelope. The resultant envelope is oftentimes readily recognized as a mass mailing by the characteristic rectangular envelope back, lacking the familiar angled flaps and edges of conventional commercial envelopes. 
     Conventional commercial envelopes, however, are typically manufactured from a single envelope sheet. This sheet is typically first printed in a web press, sheeted, and finally die cut to create a multi-sided envelope blank. An example commercial envelope includes a main body portion, a pair of oppositely located side flaps, a bottom flap, and a top flap. During manufacturing, the side flaps and bottom flap are glued, folded and sealed together to form the envelope, and the top flap is provided with a glue. Because of the required assembly steps, including multi-sided folding, commercial envelopes are not conducive to inline press manufacturing used in the integrated process. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of an example paper stock illustrating a plurality of two-piece envelope blanks. 
         FIG. 2  is a perspective view of the example two-piece envelope blank of  FIG. 1 , showing the blanks, in particular a rear panel and a front panel, removed from the paper stock prior to assembly. 
         FIG. 3A  is a perspective view of the example envelope of  FIG. 2 , showing a mailing insert being placed on a front panel of the envelope blank and being covered by the rear panel. 
         FIG. 3B  is a perspective view of the example envelope blank of  FIG. 1 , showing a rear panel of the envelope blank secured to the front panel of the envelope blank and showing a bottom flap being folded over the rear panel. [here] 
         FIG. 3C  is a side view of the example envelope, of  FIG. 3B , showing the example envelope partially folded. 
         FIG. 4  is a perspective view of the example envelope of  FIG. 2 , showing another assembly example wherein the bottom flap has been folded over the rear panel and a mailing insert is placed between the front panel and the rear panel. 
         FIG. 5  is a perspective view of the example envelope of  FIG. 2 , showing the top flap after the top flap has been folded over the rear panel to close the envelope. 
         FIG. 6  is a perspective view of another example envelope blank, showing a transparent window film, and its placement on the envelope front panel. 
         FIG. 7  is a side view of the example envelope, of  FIG. 6 , showing the example envelope partially folded. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a plurality of example envelopes  10  prior to assembly. In this example, each of the envelopes  10  are prepared from a two-piece envelope blank  12  that is removed from a paper stock, such as, for example a paper web  13 . The example envelope blank  12  includes a first envelope portion  14  and a second envelope portion  16 . The envelope blank  12  may be removed from the paper web  13  by any suitable manner, including, for example, die cutting. As illustrated, multiple envelopes  10  may be removed from the paper web  13  during manufacture. Furthermore, while the first and second envelope portions  14  and  16  are illustrated as being formed from a single web  14 , the envelope portions  14  and  16  may be formed from separate webs and/or from webs separately formed from a single web (e.g., split from a single web). Still further, all, or a portion of, the blank  12  may be removed from the web  14  at any time during assembly of the envelope  10 . The example paper web  13  is adapted to move through a single direction inline web assembly press parallel to the arrow D as shown. 
     Referring to  FIGS. 2-5 , the example envelope  10  is illustrated as removed from the web  13 . In this example, the envelope  10  is prepared from the two piece envelope blank  12  that includes the first envelope portion  14  and the second envelope portion  16 . Specifically, the example first envelope portion  14  includes a front panel  18 , a top flap  20 , and a bottom flap  22 . The example second envelope portion  16  includes a rear panel  24 . Each of the example front panel  18  and rear panel  24  are generally rectangular in shape and are of substantially the same width and height. In particular, in this example the front panel  18  and the rear panel  24  are each approximately ten inches in width and four inches in height. The width and/or the height of each of the front panel  18  and the rear panel  24 , however, may vary as desired. Furthermore, the height of the front panel  18  may be different than the height of the rear panel  24 . 
     As illustrated, the example front panel  18  includes a top edge  18   a , and a parallel bottom edge  18   b , connected by a pair of side edges  18   c  and  18   d . The example rear panel  24  similarly includes a top edge  24   a , and a parallel bottom edge  24   b , connected by a pair of side edges  24   c  and  24   d . The front panel portion  18  has an inner surface  18   e  which lies in confronting relationship with an inner surface  24   e  of the rear panel  24  after the envelope  10  is assembled as described below. Further, the example top flap  20  and the bottom flap  22  are integrally formed with the top edge  18   a  and the bottom edge  18   b  of the front panel  18  about respective fold lines  28  and  30 . As shown, the example fold lines  28  and  30  are parallel to both the top edge  18   a  and the bottom edge  18   b , and are, therefore, parallel to each other. The side edges  18   c  and  18   d  are free from any fold lines, flaps, or other appendages. 
     Each of the example top flap  20  and bottom flap  22  includes a generally triangular shaped portion. For instance, in this example the top flap  20  includes a first side edge  20   c  and a second side edge  20   d  extending from the side edges  18   c  and  18   d  of the front panel  18  respectively. The side edge  20   c  extends from the intersection of the edge  18   c  and the top edge  18   a , extending upward and convergently towards an apex  32  formed by the intersection of the side edges  20   c  and  20   d . The side edge  20   d  extends from the intersection of the edge  18   d  and the top edge  18   a , extending upward to the apex  32 . The size and/or shape of the top flap  20  may vary as desired. In this example, the distance between the apex  32  and the top edge  18   a  is approximately two inches. 
     Similarly, the bottom flap  22  includes a first side edge  22   c  and a second side edge  22   d  extending from the side edges  18   c  and  18   d  of the front panel  18  respectively. In this example, the side edge  22   c  extends from the intersection of the edge  18   c  and the bottom edge  18   b  opposite the top flap  20 . The side edge  22   d  extends from the intersection of the edge  18   d  and the bottom edge  18   b . Both side edges  22   c  and  22   d  extend downward and converge toward a bottom edge  22   b . The bottom edge  22   c  is generally parallel to the bottom edge  18   b  of the front panel  18 . In other examples, the side edges  22   c  and  22   d  may extend to an apex (not shown) thereby eliminating the bottom edge  22   b . The size and/or shape of the bottom flap  22  may vary as desired. In this example, the distance between the bottom edge  22   b  and the bottom edge  18   b  is approximately three and one half inches. 
     The example front panel portion  18  is provided with a plurality of adhesive regions for assembling the envelope  10  as will be described in detail below. For example, the example front panel portion  18  includes a first adhesive region  40   a  and a second adhesive region  40   b  for securing the rear side panel portion  24  to the front side panel portion  18 . A third adhesive region  40   c  is provided for securing the bottom flap  22  to an outer surface  24   f  of the rear panel  24 , and a third adhesive region  40   d  for securing the top flap  20  to the outer surface  24   f  of the rear panel  24  or to an outer surface of the bottom flap  22 , after the envelope  10  is assembled. Each of the adhesive portions  40   a - 40   d  may be any suitable fastener and/or adhesive, including, for example, permanent, semi-permanent, or releasable adhesive, or other suitable arrangement. While the adhesive portions  40   a - 40   d  are illustrated as contiguous regions, the adhesive portions may be placed in any suitable pattern, arrangement and/or location. For instance, while the adhesive portions  40   a - 40   d  are illustrated as being located on the inner surface  18   e  of the front panel portion  18 , any or all of the adhesive portions  40   a - 40   d  may be located on the corresponding surface of the rear panel  24 , or may alternatively be located on both surfaces. 
     Referring to  FIGS. 2-5 , two example assembly processes of the envelope  10  are shown. The example assembly processes may be performed by a high speed inline web assembly press (not shown), or other suitable automated and/or manual process. 
     In one method of forming the envelope  10 , a preformed mailer insert  50  is first aligned with and placed in proximity to the front panel portion  18  of the first envelope portion  14  as shown in  FIG. 3A . The mailer insert  50  will thus lie in confronting relationship with the inner surface  18   e . The mailer insert  50  will not overlap the adhesive layers  40   a  or  40   b , allowing for removal of the insert  50  later by a recipient of the envelope  10 . The mailer insert  50  may be any type of insert (e.g. a letter, card, billing statement, advertisement, etc.), separately or concurrently formed, and sized and/or folded for placing onto the inner surface  18   e . In the illustrated examples, the mailer insert  50  is a folded paper mailer. 
     After placement of the mailer insert  50 , the rear panel  24  is aligned with and mounted to the front panel portion  18  of the first envelope portion  14 , at least partially covering the mailer insert  50 , such that the inner surface  24   e  lies in confronting relationship with the mailer insert  50 . The rear panel portion  24  is secured to (i.e. adhered to) the front panel portion  18  by, for example, the adhesive layers  40   a  and  40   b.    
     The bottom flap  22  is then folded over the outer surface  24   f  of the rear panel portion  24  as shown in  FIGS. 3B-3C . The folding may be performed by, for example, plow folding the bottom flap  22  in the inline assembly press. The illustrated bottom flap  22  covers at least a portion of the outer surface  24   f  of the rear panel portion  24 , but also leaves at least a portion of the outer surface  24   f  uncovered. The bottom flap  22  could cover the outer surface  24   f.    
     In another example method of forming the envelope  10 , shown in  FIG. 4 , the mailer insert  50  is placed into an already formed pocket  46  bounded on three sides. In particular, the pocket  46  is formed between the rear panel portion  24  and the front panel portion  18  by the adhesion of the rear panel portion  24  to the front panel portion  18  and by the folding of the bottom flap  22 . As with the previous example, the mailer insert  50  will not overlap the adhesive layers  40   a  or  40   b.    
     In either example, the mailer insert  50  may be placed on the inner surface  18   e  or inserted into the pocket  46  in any suitable manner. For instance, the mailer insert  50  may be placed in cooperative relationship with either the front panel portion  18  or the rear panel portion  24  prior to the formation of the pocket  46  and the pocket  46  may be subsequently formed around the mailer insert  50  during the inline process ( FIG. 3A ), or the example mailer insert  50  may be inserted into the pocket  46  after the formation of the pocket  46  ( FIG. 4 ). This may be achieved by, for example, a secondary offline inserting process. 
     Turning now to  FIG. 5 , after the mailer insert  50  is assembled within the envelope  10 , the top flap  20  is folded about the fold line  28  and the envelope  10  is ready for subsequent sealing. The top flap  20  may be folded, for example, by plow folding the top flap  20  about the fold line  28 , such as, for instance, during the inline press assembly. Similar to the bottom flap  22 , the top flap  20  covers at least a portion of the outer surface  24   f  of the rear panel portion  24 . As illustrated, in this example, the top flap  22  covers a portion of the bottom flap  22  when folded. The top flap  22 , however, may not cover a portion of the bottom flap  22  when folded. With both the bottom flap  22  and the top flap  20  folded, however, at least a portion of the outer surface  24   f  of the rear panel portion  24  remains uncovered. In this manner, the back side of the assembled envelope  10  has the appearance of a standard commercial envelope. The top flap  20  may be folded and left un-sealed for later processing and/or sealing as desired. Any or all of the assembly steps may be performed by an automated process, a manual process, or a combination of both. 
     Turning now to  FIG. 6 , there is illustrated another example envelope  10 ′ similar to the envelope  10 . The envelope  10 ′ of  FIG. 6  has many similarities to the envelope  10 . Thus, to avoid redundancy, structures appearing in the envelope  10  are not again discussed in detail in the following description of the example envelope  10 ′. Instead, the intended reader is referred back to the description of the example envelope  10  for a complete description of those components. To facilitate such an effect, like reference numbers are used to reference like structures in the example envelope  10 ,  10 ′. 
     The example envelope  10 ′ of  FIG. 6  is prepared from a similar two-piece envelope blank  12 ′, but also includes a transparent window film  15 . In this example, the front panel portion  18  includes at least one window  19  formed through the panel  18 , sized and located for a mailing address and/or other information to be displayed therethrough. For example, the window  19  may allow a mailing address located on the mailer insert  50  to be displayed. 
     In this example, the window film  15  is placed over the address window  19  and adhered to the inner surface  18   e  of the front panel portion  18 . For instance, as illustrated the adhesive  40   a  is extended around at least a portion of the address window  19  and a first side of the window film  15  is adhered thereto. While the window film  15  may be sized to correspond generally to the size of the address window  19 , (i.e., only covers the window  19 ), in this example the window film  15  extends substantially the same width as the front panel portion  18 . The window film  15 , however, may be sized as desired. In this illustrated example, the window film  15  is secured to the front panel portion  18  by at least a portion of the adhesives  40   a  and  40   b . Accordingly, an adhesive  40   e  and  40   f  and/or other suitable fastener is included on the second side of the window film  15  to secure the rear panel portion  24  to the window film  15 . Thus, the example pocket  46  is formed between the window film  15  and the rear panel portion  24 . 
     As noted above, the window film  15  may be any suitable size and/or shape. For example, the window film  15  may be sized to substantially correspond to the shape of the address window  19  and blown on as a patch. Alternatively, the window film  15  may be larger or smaller than the address window  19 . Furthermore, as in this example, the window film  15  may include an adhesive  40   e ,  40   f  to assist in the securement of the rear panel portion  24  to the front panel portion  18 , and the adhesive  40   e ,  40   f  may be any pattern as desired, or may be eliminated entirely. Additionally, the window film  15  may be completely eliminated from the envelope  10 ′ and the address window  19  left uncovered. 
     Because previous envelopes manufactured by an inline press typically included a plurality of flaps that are not perpendicular to the direction of travel of the envelope through an inline press, the manufacturing of the envelope required a change of direction to properly process folds. A change of direction in the inline manufacturing process, however, leads to an increase in space, cost, complexity, and/or time, thus slowing the manufacturing process and/or making the process more costly and/or impractical. For example, to plow fold a piece of paper in an inline press, the paper must be traveling in a direction parallel to the fold. Accordingly, envelope assemblies that include flaps with fold lines perpendicular to the direction of travel require a change of direction to properly plow fold the flap. This change of direction increases the complexity of the press assembly, results in slower processing speeds, and is not conducive to large mailing projects that rely upon very fast and efficient processing times. 
     Furthermore, the characteristic rectangular envelope formed by typical inline press assemblies oftentimes is easily recognizable by a customer as a mass mailing envelope. This mass mailing classification may have negative connotations to the recipient, even when the mailing is highly relevant to the consumer. In some instances, the consumer may choose not to open the mailing, or delay doing so, simply as a result of the appearance of the mailing piece. Thus, producers of mass mailing projects desire a mailer that may be produced quickly and efficiently, while resulting in an envelope that has the appearance of a business mailer. 
     The example envelopes  10 ,  10 ′ described herein present the appearance of a commercial envelope, while allowing the envelopes  10 ,  10 ′ to be mass produced at typical inline press speeds. In particular, the example envelopes  10 ,  10 ′ include flaps and fold lines that are parallel to the direction of travel of the envelopes  10 ,  10 ′ within the inline press. The envelopes  10 ,  10 ′ are processed in a single direction through the inline press, allowing the press to run at a normal process rate, suitable for large mailing projects. Additionally, the appearance of the example envelopes  10 ,  10 ′ mimic that of a traditional commercial envelope. In particular, the example envelopes  10 ,  10 ′ are produced with a quickly recognizable commercial, or “diaper” envelope back. 
     Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.