Patent Publication Number: US-2005116015-A1

Title: Eccentric fold, pressure-seal mailer with built-in envelope

Description:
RELATED PRIOR APPLICATION  
      This application claims priority to provisional patent application Ser. No. 60/514,567, filed Oct. 27, 2003, which is incorporated herein in its entirety by reference. 
    
    
     FIELD OF THE INVENTION  
      The invention relates to a single ply mailer having a built-in envelope that allows for simplex printing.  
     BACKGROUND OF THE INVENTION  
      Many business forms are constructed as mailers that are used for a variety of purposes including sending information via the U.S. Postal Service to addressees and other recipients who may have interest in such information. The mailers may embody advertising and marketing materials, invoices and billing statements, financial and bank statements, registration forms and any other types of information and data that may be useful to addressees or intended recipients. Prior art mailers typically constitute two types of designs including continuous business forms and cut sheet business forms. Continuous business forms include a series of mailers that are connected together by a single ply of continuous paper or web or a number of superimposed plies that similarly form a continuous paper or web. The continuous paper or web is processed via a number of processes including printing, folding and gluing. During such processing individual mailers are cut from the continuous paper or web to form individual mailers. In contrast, cut sheet business forms are individual mailers formed of a singly ply or multiple superimposed plies that are processed separately.  
      Many continuous and cut sheet business form designs include an envelope disposed within an interior of a mailer that may serve, for instance, as a return envelope configured to receive a variety of forms, such as a coupon, a payment stub, a registration form or other insert, to be returned to the sender of the mailer. In many cases, envelopes of prior art designs include one or more panels adhered to a body of a base mailer to form an envelope within the interior of the mailer when it is assembled. Such mailers require additional plies to be added to the base mailer, e.g., adhered to the base mailer with various strips or dots of adhesive disposed along certain portions of the base mailer, to form the envelope, as well as require one or more tabs or panels to form and/or to seal the envelope for use. Such designs typically involve a number of steps in a production process and utilize additional panels of a substrate such a paper from which the mailer is formed. In other cases, envelopes are created by folding the bottom panel similar to a “C-fold” construction. Such mailers require either duplex imaging or the use of a window to have the outgoing address on the outgoing envelope while variable information is secured inside the closed mail piece.  
     SUMMARY OF THE INVENTION  
      An object of the invention is to provide an improved mailer. Another object of the invention is to provide an improved mailer having an internal, built-in envelope. A further object of the invention is to provide a single ply, multi-fold mailer that forms a built-in envelope as a consequence of folding the single ply. Still another object of the invention is to provide a single ply mailer defining four panels that form a built-in envelope as a consequence of folding along certain fold lines and adhering certain strips or dots of adhesive. Yet another object of the invention is to provide a single ply form that is capable of being simplex imaged having images along an outgoing envelope portion, a reply envelope portion and along a statement or stub portion.  
      In general, in an aspect, the invention provides a mailer that is capable of simplex imaging without use of a window by providing an outgoing address and a stub on the same side or surface of a single ply or sheet of paper, a document or other substrate. In addition, the invention provides a mailer with a generic return envelope formed within its interior when assembled that may be simplex imaged at the same time as an outgoing envelope, which provides billing and mailing services to reduce inventory without the increased costs of duplex imaging. The mailer according to the invention may be simplex imaged with either one of its outer edges, e.g., a first or top edge or a second or bottom edge with respect to the length of the mailer, serving as a top edge of the mailer to orient graphics and/or fonts in a manner that helps to support a mailer design and/or a laser printer. Further, the mailer according to the invention supports imaging a “return address” along a reply envelope portion of the mailer that allows an end-user&#39;s or recipient&#39;s name and/or account number or other information to be identified along the reply envelope portion to provide such information to the sender, e.g., in the event the end-user or recipient does not include, for instance, a return insert, coupon or stub that bears such information. The invention further provides a mailer that is constructed of a single ply or sheet that is substantially flat to thereby help to reduce or eliminate a raised stack height and related problems that are associated with patch reply envelopes when a plurality of mailers according to the invention are stacked, e.g. one on top of another.  
      Various aspects of the invention provide one or more of the following capabilities. A single ply, multi-fold mailer is provided that includes a built-in envelope such that upon opening and unfolding the mailer when assembled, the envelope is intact and freestanding for use. A single ply mailer is configured for use with an in-line production process, which includes printing information and indicia along one or more surfaces of the mailer and folding the mailer along a number of fold lines and along a number of strips or dots of adhesive, to form the mailer and to define a built-in envelope within the interior of the mailer. A single ply, multi-fold mailer is provided that can help to reduce manufacturing costs.  
      These and other capabilities of the invention, along with the invention itself, will be more fully understood after a review of the following figures, detailed description, and claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a plan view of a first surface of a mailer according to one aspect of the invention illustrating four panels;  
       FIG. 2  is a plan view of a second surface of the mailer shown in  FIG. 1  illustrating four opposing panels;  
       FIG. 3  is a plan view of the first surface of the mailer shown in  FIG. 1  illustrating various fold lines and lines of weakening;  
       FIG. 4  is a plan view of the first surface of the mailer shown in  FIG. 1  illustrating overall dimensions;  
       FIG. 5  is a plan view of the first surface of the mailer shown in  FIG. 1  illustrating other overall dimensions;  
       FIG. 6  is a plan view of the first surface of the mailer shown in  FIG. 1  illustrating still further overall dimensions;  
       FIG. 7  is a plan view of the first surface of the mailer shown in  FIG. 1  illustrating positions of strips or dots of adhesive;  
       FIG. 8  is a plan view of the second surface of the mailer shown in  FIG. 2  illustrating positions of strips or dots of adhesive;  
       FIG. 9  is a plan view of the first surface of the mailer shown in  FIG. 1  with additional positions of strips or dots of adhesive;  
       FIG. 10  is a perspective view of folding the mailer shown in  FIG. 1  along one set of fold lines;  
       FIG. 11  is a perspective view of folding the mailer shown in  FIG. 10  along a second set of fold lines;  
       FIG. 12  is a plan view of the mailer shown in  FIG. 11  fully assembled and partially torn along lines of weakness;  
       FIG. 13  is plan view of the mailer shown in  FIG. 12  unfolded along one set of fold lines;  
       FIG. 14  is a plan view of the mailer shown in  FIG. 13  with a panel partially removed therefrom;  
       FIG. 15  is a plan view of the mailer shown in  FIG. 14  with a second panel partially removed therefrom;  
       FIG. 16  is a plan view of a freestanding, built-in envelope of the mailer shown in  FIG. 15 ; and  
       FIG. 17  is a plan view of the envelope shown in  FIG. 16  with a portion of one of the panels removed being inserted therein. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
      Embodiments of the invention provide a mailer constructed as a multi-fold, single unit for use in distribution of information and data of potential interest to recipients of the mailer. A mailer according to the invention is a single ply or sheet including four panels and multiple parallel fold lines traversing the panels, and further includes multiple strips or dots of adhesive disposed longitudinally along certain portions of the panels. Folding panels along certain fold lines and mating certain strips or dots of adhesive help to form an assembled mailer. In one aspect, the mailer according to the invention includes multiple parallel fold lines to permit the single ply to doubly fold to form, for instance, a double V-fold configuration of the mailer. In addition, the mailer according to the invention further includes a built-in envelope or other insert disposed within the mailer and configured such that the envelope may be used when the mailer is opened or unfolded. Other embodiments are within the scope of the invention.  
      The term “adhesive” used to disclose various aspects of the invention refers to an adhesive or cohesive that is activated or provides cohesion to adhere to a surface with an application of a pressure or force to the adhesive or cohesive. Such adhesives and cohesives also include re-sealable adhesives and cohesives. In addition, the term adhesive can also refer to a wettable or rewettable adhesive or cohesive that is activated for adhesion with an application of moisture or water.  
      Referring to  FIGS. 1 and 2 , in one aspect, the invention provides a mailer  101  including a first surface  1  and a second surface  2 . In one configuration, the first surface  1  is configured to be printed with information and images including address information and other information and data of potential interest to a recipient of the mailer  101 . The first surface  1  serves primarily as an outer surface of the mailer  101  when the mailer  101  is assembled. The second surface  2  is also configured to be printed with information and images and may also include information and data. The second surface  1  serves primarily as a second or interior surface of the mailer  101  when the mailer  101  is assembled.  
      In one configuration, the mailer  101  is formed of a single ply or sheet of paper or other substrate constructed for printing by any of a variety of printers and methods or techniques well known in the art. In particular, the mailer  101  may be formed as a single ply or sheet from a continuous paper web or other substrate that may be used, for instance, in a continuous printing process that is incorporated in-line with a production and assembly method of the mailer  101  whereby the mailer  101  is cut from the continuous web during one phase of production.  
      Referring to  FIG. 3 , and with further reference to  FIGS. 1 and 2 , in one configuration, the mailer  101  includes four panels  2 ,  4 ,  5  and  7  whose surfaces comprise the first surface of the mailer  101 . As shown in  FIGS. 1 and 3 , each panel  2 ,  4 ,  5  and  7  is defined by multiple parallel fold lines that traverse the panels  2 ,  4 ,  5  and  7  horizontally along a width of each panel  2 ,  4 ,  5  and  7 . A first or top panel  2  is defined between a first or top outer edge  102  of the mailer  101  and a first fold line  18 . A second or middle panel  4  and a third or middle panel  5  are disposed adjacent to the first or top panel  2 . The second or middle panel  4  is defined between the first fold line  18  and a second fold line  19 . The third or middle panel  5  is defined between the second fold line  19  and a third fold line  20 . A fourth or bottom panel  7  is defined between a fourth fold line  21  disposed just below the third fold line  20 , as shown in  FIGS. 1 and 3 , and a second or bottom outer edge  103  of the mailer  101 .  
      As shown in  FIG. 2 , fold lines  18 ′,  19 ′,  20 ′ and  21 ′ defined along the second surface  2  of the mailer  101  are disposed at positions that correspond to the fold lines  18 ,  19 ,  20  and  21  defined along the first surface  1 . The corresponding fold lines  18 ′,  19 ′,  20 ′ and  21 ′ similarly define multiple panels  10 ,  11 ,  12 , and  14  whose surfaces form the second surface  2  of the mailer  101 . The multiple panels  10 ,  11 ,  12  and  14  are essentially the opposite surfaces of the panels  2 ,  4 ,  5  and  7  along the first surface  1 . A first or top panel  10  is defined between the first or top outer edge  102  of the mailer  101  and a first fold line  18 ′. A second panel  11  is defined between the first fold line  18 ′ and a second fold line  19 ′ defined along the second surface  2 . A third panel  12  is defined between the second fold line  19 ′ and a third fold line  20 ′, and a fourth panel  14 ′ is defined between a fourth fold line  21 ′ disposed just below the third fold line  20 ′ and the second or bottom outer edge  103  of the mailer  101 .  
      The fold lines  18 ,  19 ,  20  and  21  along the first surface  1  and the fold lines  18 ′,  19 ′,  20 ′ and  21 ′ along the second surface  2  help to permit the mailer  101  to fold along a width of the mailer  101  to form a required or desired configuration. The fold lines  18 ,  19 ,  20  and  21  and  18 ′,  19 ,  20  and  21  may include printed lines or other demarcations to identify the axes traversing the width of the mailer  101  along which the mailer  101  is to be folded. Alternatively, or in addition, one or more of the fold lines  18 ,  19 ,  20  and  21  and  18 ′,  19 ′,  20 ′ and  21 ′ may include lines of weakness, embossing or lines of perforations defined in the mailer  101  that help to facilitate folding of the mailer  101  along one or more of the fold lines  18 ,  19 ,  20  and  21  and  18 ′,  19 ′,  20 ′ and  21 ′ and/or to facilitate removal of one or more of the panels  2 , 10  and  4 ,  11  and  5 ,  12  and  7 , 14  from the mailer  101 , as will be described below in more detail. In one configuration, the lines of perforations that serve as one or more of the fold lines  18 ,  19 ,  20  and  21  and  18 ′,  19 ′,  20 ′ and  21 ′ are not through perforations defined from the first surface  1  to the second surface  2 .  
      With further reference to  FIGS. 2 and 3 , a first longitudinal line of weakness  15  is defined along the mailer  101  adjacent to a first side edge  104 . The line of weakness  15  bounds an area  43  between the first side edge  104  and the line of weakness  15 . As will be described below in more detail, one or more strips or dots of adhesive are disposed along the area  43 . A second longitudinal line of weakness  16  is defined along the mailer  101  adjacent to a second side edge  105 , and bounds an area  42  between the second side edge  105  and the line of weakness  16 . Similarly, as will be described below, one or more strips or dots of adhesive are disposed along the area  42 . The longitudinal lines of weakness  15  and  16  are disposed and configured to permit an end-user to tear the mailer  101  along the lines weakness  15  and  16  to open the mailer  101  as required or desired when the mailer  101  is assembled. The first and the second longitudinal lines of weakness  15  and  16  may include lines of embossing and/or lines of perforations that are defined along the surfaces  1  and  2  to facilitate tearing along the lines l 5  and  16  to unfold the mailer  101 . In one configuration, the lines of weakness  15  and  16  include lines of embossing and/or lines of perforations that extend from the first surface  1  through to the second surface of the mailer  101 . In addition, printed lines or other demarcations may be used to further identify the lines of weakness  15  and  16  and to indicate the lines  15  and  16  along which the assembled mailer  101  is to be torn to unfold the mailer  101  as required or desired.  
      With further reference to  FIG. 2 , an area defined between the third fold line  20 ′ and the fourth fold line  21 ′ along the second surface  2  includes an area or strip  13  between the third panel  5 , 12  and the fourth panel  7 ,  14  that has one or more strips or dots of adhesive  13 ′, such as re-wettable adhesive, to help to permit portions of the mailer  101 , e.g., the second panel  4 ,  11  and the third panel  5 ,  12 , to serve as a built-in envelope or other insert disposed within the interior of the mailer  101  when the mailer is  101  assembled, as will be described below in more detail. The one or more strips or dots of adhesive  13 ′ help the area  13  to serve as an over flap to seal the built-in envelope and to secure any contents therein.  
      Referring to  FIGS. 4, 5  and  6 , dimensions of configurations of the mailer  101  according to the invention are illustrated. As shown in  FIG. 4 , in one configuration, the mailer  101  includes overall dimensions measuring a length L 1  of about 14 inches and a width W 1  of about 8.5 inches. A further configuration of the mailer  101  shown in  FIG. 5  includes the mailer  101  having a length L 2  of about 17 inches and a width W 2  of about 8.5 inches. Another configuration of the mailer  101  is shown in  FIG. 6  including a length L 3  of about 17 inches and a width W 3  of about 11 inches. A length (or height) of each panel  2 ,  4 ,  5  and  7  and  10 ,  11 ,  12  and  14  of the mailer  101  shown in  FIG. 5  that defines a length L 2  of about 17 inches is substantially the same as a length (or height) of each panel  2 ,  4 ,  5  and  7  and  10 ,  11 ,  12  and  14  of the mailer  101  shown in  FIG. 6  that defines a length L 3  of about 17 inches. The dimensions of the mailer  101  illustrated in  FIGS. 4, 5  and  6  are instances of preferred dimensions.  
      The invention is not limited to these dimensions of the mailer  101  or of the panels  2 ,  4 ,  5  and  7  and  10 ,  11 ,  12  and  14 , and envisions that the mailer  101  and each panel  2 ,  4 ,  5  and  7  and  10 ,  11 ,  12  and  14  can define other lengths (or heights) and widths that are conducive to its position and purpose relative to the mailer  101  when the mailer  101  is assembled.  
      Referring to  FIG. 7 , positions of multiple strips or dots of adhesive are illustrated along the first surface  1  of the mailer  101 . One or more strips or dots of adhesive  24  are disposed longitudinally along the area  43  adjacent to the first panel  2  defined between the line of weakness  15  and the first side edge  104  and between the first or top outer edge  102  and the first fold line  18 . One or more strips or dots of adhesive  26  are also disposed adjacent to the first panel  2  and longitudinally along the area  42  defined between the line of weakness  16  and a second side edge  105  and the first or top outer edge  102  and the first fold line  18 . Similarly, as shown in  FIG. 7 , one or more strips or dots of adhesive  25  are disposed adjacent to the second panel  4  and longitudinally along the area  43  defined between the line of weakness  15  and the first side edge  104  and between the first fold line  18  and the second fold line  19 . The area  42  adjacent to the second panel  4  defined between the line of weakness  16  and the second side edge  105  and between the first fold line  18  and the second fold line  19  similarly includes strips or dots of adhesive  27  disposed longitudinally.  
      The strips or dots of adhesive  24 ,  25 ,  26  and  27  disposed along the areas  42  and  43  are further positioned such that when the mailer  101  is folded along the first fold line  18 , in the direction indicated by arrow  200  shown in  FIG. 7 , the strips or dots  24  and  26  adjacent to the first panel  2  mate with the strips or dots  25  and  27  adjacent to the second panel  4 . Folding the mailer  101  along the first fold line  18  also places the first panel  2  along the first surface of the mailer  101  in facing relationship and flush with the second panel  4 .  
      With further reference to  FIG. 7 , additional strips or dots of adhesive  44  and  45  are disposed along the areas  42  and  43 , respectively, adjacent to the second panel  4  in order to help to provide further secure attachment of the first panel  2  with the second panel  4  when folded and mated as described above.  
      Referring to  FIG. 8 , multiple strips or dots of adhesive are disposed along the second surface  2  of the mailer  101 . In one configuration, the second surface  2  of the mailer  101  includes strips or dots of adhesive  31  and  32  disposed longitudinally along the area  43  defined by the first line of weakness  15  and the first side edge  104 . Similarly, in this configuration, strips or dots of adhesive  29  and  30  are disposed longitudinally along the area  42  defined by the second line of weakness  16  and the second side edge  105 .  
      Additional strips or dots of adhesive  33 ,  34 ,  35  and  36  are disposed longitudinally along each side of the second panel  11  and the third panel  12 . As shown in  FIG. 8 , the strips or dots of adhesive  33  and  34  are disposed longitudinally in the second and third panels  11  and  12  adjacent to the first line of weakness  15  and outside of the area  43  defined between the first side edge  104  and the first line of weakness  15 . In addition, the strips or dots of adhesive  35  and  36  are disposed longitudinally in the second and third panels  11  and  12  adjacent to the second line of weakness  16  and outside of the area  42  defined between the second side edge  105  and the second line of weakness  16 .  
      The strips or dots of adhesive  33  adjacent to the second panel  4  mate with the strips or dots of adhesive  34  adjacent to the third panel  5  when the mailer  101  is folded along the second fold line  19 ′ in the second surface  2 . Also, the strips or dots of adhesive  35  adjacent the second panel  4  mate with the strips or dots of adhesive  36  when the mailer  101  is folded along the second fold line  19 ′.  
      The strips or dots of adhesive  33 ,  34 ,  35  and  36  in the second and third panels  11  and  12  along the second surface  2  help to form an envelope within the interior of the mailer  101  from the second and third panels  4 ,  11  and  5 ,  12  when the mailer is assembled, as will be described below in more detail.  
      Still referring to  FIG. 8 , one or more strips or dots of adhesive  38  are disposed in the second surface  2  of the mailer  101  across the fourth panel  14  adjacent to the second or bottom outer edge  103 . One or more strips or dots  40  are also disposed within the area  43  adjacent to the line of weakness  15  proximate to a corner or intersection of the first side edge  104  and the second or bottom outer edge  103 . Similarly, one or more strips or dots  39  of adhesive are also disposed within the area  42  adjacent to the line of weakness  16  proximate to a corner or intersection of the second side edge  105  and the second or bottom outer edge  103 . Although optional, the strips or dots  39  and  40  help to assemble the mailer  101  and to secure the mailer  101  when the mailer  101  is assembled by mating with the strips or dots  44  and  45 , respectively, disposed along the first surface  1  of the mailer  101 .  
      Referring in  FIG. 9 , in another configuration of the mailer  101 , additional strips or dots of adhesive  24 ,  25 ,  26  and  27  are disposed adjacent to the first and the second panels  10  and  11  along the second surface  2 . Multiple strips or dots of adhesive  24  and  25  are disposed in the area  43 , and multiple strips or dots of adhesive  26  and  27  are disposed in the area  42 . The strips or dots of adhesive  24  and  26  adjacent the first panel  10  mates with the strips or dots  25  and  27  adjacent the second panel  11  help to secure the mailer  101  when assembled.  
      The invention is not limited to the locations of the strips or dots of adhesive along the first surface  1  and the second surface  2  of the mailer  101  as shown in  FIGS. 8 and 9 , and anticipates that strips or dots of adhesive may be located along other portions of the first and the second surfaces  1  and  2  to help to assemble and secure the mailer  101  and to help to maintain certain panels of the mailer  101  intact when the assembly mailer  101  is tom along the lines of weakness  15  and  16  and unfolded.  
      Referring to  FIGS. 10 and 11 , formation of the mailer  101  is illustrated. In one configuration, the mailer  101  may be folded initially along the second fold lines  19  and  19 ′ of the first and second surfaces  1  and  2  in a direction shown by arrow  205  in  FIG. 10  to place the surfaces of the first and second panels  10  and  11  in contact or flush with the surfaces of the third and fourth panels  12  and  14 . In this case, the mailer  101  is essentially folded in half along the second fold lines  19  and  19 ′. As shown in  FIG. 11 , the mailer  101  is further folded along the first fold lines  18  and  18 ′ and the third fold lines  20  and  20 ′ in a direction shown by arrow  210  in  FIG. 11  to place the surface of the first panel  2  in contact or flush with the surface of the second panel  4 . The surfaces of the third panel  5  and the fourth  7  along the first surface  1 , as a result, define the outer surfaces of the mailer  101  when the mailer  101  is assembled.  
      During folding of the mailer  101 , as described above with reference to  FIGS. 10 and 11 , strips or dots of adhesive disposed along the second surface  2  are mated. Specifically, as a result of the mailer  101  being folded along the second fold lines  19  and  19 ′ in the direction shown by arrow  205 , the strips or dots of adhesive  29  and  31  disposed along the areas  42  and  43 , respectively, adjacent to the first and the second panels  10  and  11  are placed in contact or mate with the strips or dots of adhesive  30  and  32  disposed along the areas  42  and  43 , respectively, adjacent to the third and the fourth panels  12  and  14 . In addition, as a result of the mailer  101  being folded along the second fold lines  19  and  19 ′, the strips or dots of adhesive  33  and  35  disposed adjacent to the second panel  11  are placed in contact or mate with the strips or dots of adhesive  34  and  36  disposed adjacent to the third panel  12 .  
      In one aspect of the invention, during or after the mailer  101  is folded as described above, a pressure or force is applied to the mailer  101  to help to achieve folding along the fold lines as noted, and to help to mate and adhere the strips or dots of adhesive with one another to secure the panels and to thereby assemble the mailer  101 . In this case, the adhesive includes a pressure seal adhesive formulated to adhere to a surface. e.g., with adhesive disposed thereon, when a pressure or force is applied to the adhesive. The invention is not limited to pressure sensitive adhesive and envisions that other types or formulations of adhesive other than or in addition to a pressure sensitive adhesive may be used to form the mailer  101 .  
      Still referring to  FIGS. 10 and 11 , and with further reference to  FIGS. 4, 5  and  6 , the dimensions of the panels  2 , 10 , and  4 ,  11  and  5 ,  12  and  7 ,  14  may define a length or height such that the total length or height of the first and second panels  2 ,  10  and  4 ,  11  is less than the total length or height of the third and fourth panels  5 ,  12  and  7 ,  14  and the length or height of the area  13 . When the mailer  101  is folded along the second fold lines  19  and  19 ′, as described above with reference to  FIG. 10  and as shown by arrow  205 , the first and second panels  2 ,  10  and  4 ,  11  contact and lay flush with the third and fourth panels  5 ,  12  and  7 , 14  such that a lip portion  50  of the fourth panel  7 ,  14 , as will be discussed below in more detail, remains extended from the folded mailer  101  and the strips or dots of adhesive  38  along the fourth panel  14  adjacent to the second or bottom outer edge  103  are exposed. As shown in  FIG. 12 , the strips or dots of adhesive  38  are exposed such that the strips or dots of adhesive  28  disposed along the second panel  12  adjacent to the second fold line  19 ′ couple to and mate with the strips or dots of adhesive  38  when the mailer  101  is further folded along the first fold lines  18  and  18 ′ and the third fold lines  20  and  20 ′ in the direction shown by arrow  210  to help to secure the mailer  101  in its assembled configuration.  
      As shown in  FIGS. 4, 5  and  6 , the total length L 1  of the first and second panels  2 , 10  and  4 ,  11  is shorter than the total length L 2  of the third and fourth panels  5 ,  12  and  7 ,  14  that includes an area or strip  6  along the second surface  2 , which is opposite to the area or strip  13  along the first surface  1 . The shorter total the length L 1  of the first and second panels  2 ,  10  and  4 ,  11  helps to form a lip portion  50  along a portion of the fourth panel  7 ,  14  adjacent to the bottom edge  103  of the mailer  101 . As shown in  FIG. 11 , when the mailer  101  is folded along the first fold line  18 ,  18 ′ and the third fold line  20 ,  20 ′ to accomplish a double-fold of the mailer  101  into a V-configuration, the lip portion  50  with the strips or dots of adhesive  38  disposed along the lip portion  50  mate with the strips or dots of adhesive  29  disposed along the second panel  4 ,  11  adjacent to the second fold line  19 .  
      As shown in  FIG. 11 , when the mailer  101  is assembled, the lip portion  50  helps to serve as an opening flap along an edge  101 ′ of the assembled mailer  101 . The lip portion  50 , for instance, has sufficient length to permit an end-user or recipient of the mailer  101  to slip a portion of his/her finger between the lip portion  50  and the other panels of the mailer  101  and to permit the end-user or recipient to drag the portion of his/her finger at the lip portion  50  along at least a portion of the edge  101 ′ to help to disengage the strips or dots of adhesive  38  and to thereby open the mailer  101 . The lip portion  50  essentially helps to insure that the mailer is opened with ease and without inappropriate tearing of the mailer  101 .  
      With further reference to  FIGS. 4, 5  and  6 , the second and third panels  4 , 11  and  5 , 12  define a length that are sufficient to permit the mailer  101  to be mailed, while the length is short enough to send the mailer  101  through the U.S. Postal Service. Further, in one configuration, each of the second and the third panels  4 ,  11  and  5 ,  12  define approximately the same length in order to help to align the fold lines  18 ,  18 ′ and  20 ,  20 ′ during the second fold, as shown in  FIG. 11 . In general, the first panel  2 ,  10  may define the longest length of the mailer  101  to help to maximize an area for imaging.  
      In one configuration of the mailer  101 , the total length L 1  may be shorter than the total length L 2  by constructing each of the first panel  2 , 10  and the fourth panel  7 ,  14  with a shorter length than the length of each of the second panel  4 ,  11  and the third panel  5 , 12 . The invention envisions other configurations to render the total length L 1  shorter than the length L 2  .  
      Referring to  FIG. 12 , an assembled mailer  101  is shown with areas  42  and  43  of the assembled mailer  101  being removed as a consequence of tearing the mailer  101  along the lines of weakness  15  and  16 . The folding scheme described above permits the third panel  5  and the fourth panel  7  (not shown) along the first surface  10  to form the outer or external surfaces of the mailer  101 .  
      Referring to  FIG. 13 , the open mailer  101  is shown that results when the areas  42  and  43  are removed from the mailer  101  and the mailer  101  is unfolded along the first fold lines  18  and  18 ′ and the third fold lines  20  and  20 ′. The first panel  2  and the second panel  4  of the first surface  1  are thereby exposed. On the opposite side of the open mailer  101 , the third panel  5  (not shown) and the fourth panel  7  (not shown) are also exposed. In addition, the strips or dots of adhesive  38  disposed along the fourth panel  14  of the second surface  2  are exposed.  
      As shown in  FIGS. 13 and 14 , in one configuration, the first panel  2  may serve as an insert, e.g., a billing statement, an order form or other information bearing configuration, disposed within the mailer  101  that is accessed when the mailer  101  is unfolded as described above. The first panel  2  may be further configured to define a portion  3  with a line of weakness  17  whereby the portion  3  can serve as a removable tab, coupon, stub or other configuration that is separated from the first panel  2  when the portion  3  is torn along the first fold lines  18  and  18 ′ and the line of weakness  17 , as shown in  FIG. 14 , to remove the portion  3  from the first panel  2  and the mailer  101 . In addition, the first panel  2  may be completely removed from the mailer  101  when torn along the first fold lines  18  and  18 ′. In this case, the first fold lines  18  and  18 ′ are defined as lines of weakening including, but not limited to, lines of embossing or perforations, that permit the first panel  2  to be removed from the mailer  101 . As shown in  FIGS. 13 and 14 , the portion  3  is sized for insertion into a built-in envelope  300  formed by the second panel  4 ,  11  and the third panel  5 ,  15  when the mailer  101  is assembled and thereafter unfolded as described above. The built-in envelope  300  is described below in more detail.  
      With further reference to  FIG. 15 , when the first panel  2 ,  10  and the insert or tab  3  are removed from the mailer  101 , the fourth panel  7 ,  14  is exposed and can be removed from the mailer  101  along the fourth fold lines  21  and  21 ′. In this case, the fourth fold lines  21  and  21 ″ along the first and the second surfaces  1  and  2  are lines of weakening including, but not limited to, lines of embossing or perforations, that permit the fourth panel  7 ,  14  to be removed from the mailer  101  when the mailer  101  is torn along the fourth fold lines  21  and  21 ′.  
      Referring to  FIGS. 16 and 17 , and with further references to  FIGS. 14 and 15 , with removal of the first panel  2 ,  10  and the insert or tab  3 , and removal of the fourth panel  7 ,  14 , the built-in envelope  300  results with surfaces of the second and third panels  4  and  5  exposed along the outside of the envelope  300  and surfaces of the second and third panels  11  and  12  disposed within the interior of the envelope  300 . During folding of the mailer  101  as described above, the surfaces of the second and third panels  11  and  12  are placed in contact or mate with one another. In addition, the strips or dots of adhesive  33  and  35  along the surface of the second panel  11  contact or mate with the strips or dots of adhesive  34  and  36  along the surface of the third panel  12 . Upon an application of force or pressure to the strips or dots of adhesive  33 ,  34 ,  35  and  36 , the second panel  11  is adhered to the third panel  12 . The surfaces of the adhered second and third panels  4 , 11  and  5 ,  12  define an enclosed interior bound along the strips or dots of adhesive  33 ,  34 ,  35  and  36  and the third fold line  19  and  19 ′. The built-in envelope  300 , as shown in  FIGS. 16 and 17 , is thereby formed from the adhered second and the third panels  4 ,  11  and  5 ,  12 .  
      The positions of the strips or dots of adhesive  33 ,  34 ,  35  and  36  permit the second and the third panel  4 ,  11  and  5 ,  12  to remain adhered to one another when the areas  42  and  43  are removed from the assembled mailer  101  along the lines of weakness  15  and  16  to open the mailer  101 . The built-in envelope  300  thereby remains intact when the mailer  101  is opened and unfolded as described. In addition, the strips or dots of adhesive  13  located between the third fold line  20 ′ and the fourth fold line  21 ′ along the second surface  2  are exposed when the mailer  101  is opened and unfolded. Further, access to the interior of the built-in envelope  300  is provided by an opening  302  defined by the second and the third panels  4 ,  11  and  5 ,  12  that is available with the removal of the first panel  2 ,  10  and the tab or insert  3 , as shown in  FIG. 14 .  
      As shown in  FIGS. 16 and 17 , when the first panel  2 ,  10 , the insert or tab  3 , and the fourth panel  7 ,  14  are removed from the mailer  101 , the built-in envelope  300  is freestanding. The first panel  2 ,  10  and/or the tab  3  may be inserted into the interior of the built-in envelope  300  through the opening  302 . The third panel  5 ,  12  may be folded along the fourth fold line  21 ,  21 ′ to contact or mate the strips or dots of adhesive  13 ′ with the surface of the second panel  4  to adhere the strips or dots of adhesive  13 ′ to the second panel  4  to thereby seal the built-in envelope  300 , as shown in  FIG. 17 .  
      Depending upon the purpose or function of the built-in envelope  300 , the surfaces of the second and third panel  4  and  5  along the first surface  1  may include return address information and other information or indicia, such as, for instance, a meter stamp indicating prepaid postage. In addition, the surfaces of the first panel  2  and the insert or tab  3  may include information and indicia to form, for instance, an invoice or statement, as noted above, with the insert or tab  3  being configured to serve as a payment coupon or stub for insertion into the built-in envelope  300  to be mailed along with a payment.  
      The invention is not limited with respect to the information and indicia printed on or otherwise displayed along the surfaces of the panels  4 ,  10 , and  4 ,  11 , and  5 ,  12  and  7 ,  14  and envisions such panel surfaces may include any information or indicia to serve one or more purposes. Further, the built-in envelope  300  as described herein can serve any of a number of purposes. For instance, in another aspect, the invention may provide the built-in envelope with one or more inserts contained therein.  
      Having thus described at least one illustrative embodiment of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements are intended to be within the scope and spirit of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention&#39;s limit is defined only in the following claims and the equivalents thereto.