Patent Publication Number: US-6209779-B1

Title: Laminated mailer blank with transparent window

Description:
RELATION TO OTHER PATENT APPLICATIONS 
     This is a continuation-in-part of U.S. patent application Ser. No. 09/132,036, filed Aug. 11, 1998, which is a continuation-in-part of U.S. patent application No. 08/434,416 filed May 3, 1995, now U.S. Pat. No. 5,791,553, which is a continuation-in-part of U.S. patent application Ser. No. 08/240,869, filed May 10, 1994, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a flat, laminated sheet for being folded into a mailer with a transparent window, and more particularly to providing such a sheet in a form which can be fed reliably through printing and folding devices. The subject invention further relates to such mailers having a detachable return receipt post card integral therewith. 
     2. Description of the Prior Art 
     A number of different types of mailer blanks are used to provide mailers after suitable printing and folding operations. A typical mailer, after the printing operations are completed, includes at least some variable information, such as the address of the individual to whom the mailer will be sent. The mailer may also have fixed information, which is applied in an identical manner to a large number of mailers. 
     It is often particularly desirable to print the address to which the mailer is being sent, along with other variable information as needed, on a part of the mailer blank which becomes the inside of an envelope structure after the folding processes are completed. Often, a transparent window is provided on a part of the mailer blank through which a portion of the printed information can be viewed after the printing and folding processes are completed. Such a window is conventionally formed by adhesively attaching a transparent sheet of plastic or cellulose material to extend across an aperture which has been die cut in the sheet of paper forming the mailer blank. By properly aligning the printing, the address information can be read through the transparent window positioned opposite to the address information after folding. In this way, it becomes unnecessary to print variable information on both sides of the mailer blank; rather, all such information is printed on the surface which becomes the inside of the envelope structure, thereby saving a printing step. 
     For example, when a mailer of the type just described is used to distribute checks, the name and address of the recipient may be visible both as the location to which the mailer is addressed and as the payee of the check. Upon receipt, the envelope is opened and the check portion is separated from the remaining portion of the mailer by tearing along a perforated line. Other variable information, such as the amount of the check and account numbers is printed on the same side of the mailer blank as the check, but is concealed when mailer is folded for mailing. 
     U.S. Pat. No. 4,951,864 to Dicker describes apparatus a typical prior art mailer blank and the folding and sealing thereof. Dicker&#39;s mailer blank includes remoistenable glue strips on the longitudinal sides and one traverse side of the blank, which strips are moistened prior to folding into a mailer envelope. A window aperture shown within the mailer is formed by adhesively attaching a transparent sheet to extend across a rectangular opening in the paper of the mailer. However, the transparent sheet overlaps the opening, being adhesively attached to the paper around the opening, causing the localized increase in thickness. 
     A particular problem with a conventional mailer blank of the type described above arises as a result of the additional thickness of the transparent sheet used to form the window. A typical mailer blank is made from 0.004 inches thick paper stock and 0.001 inch thick transparent sheet attached by an adhesive around an aperture in the paper stock. Thus, around the edges of the aperture, where the paper stock and the transparent sheet overlap, the thickness of the mailer blank is increased by 0.001 inch, or 25 percent of the paper thickness. Because of this difference in thickness, the mailer blanks do not lie flat when they are stacked for feeding into the, apparatus used for the printing and folding apparatus. They further do not lie flat when stored as inventory or shipped from the point of manufacture to the end user&#39;s facilities. Even if shims are used in packing, the mailer blanks generally have a permanent curl when they are removed from the cartons in which they are shipped and stored. 
     More recently, it has become common practice for a company such as an insurance company or other organization, to provide an identification card (ID card) to an individual wherein the ID card bears a particular identification number, e.g., a membership or account number, that can be used in storing or retrieving a computerized record relating to that individual. These ID cards are typically manufactured in bulk, preprinted, and inserted into a mailing envelope. 
     Moreover, this previous method of providing an ID card increases the number of steps involved in producing individualized mailers. Specifically, the address or other information provided on the mailer must be printed separately from the ID card. The ID card must then be inserted into the mailer, which involves yet another step. This can also result in mismatches between the mailer confirmation and the ID card information that may cause loss of further time and effort in correcting the error. 
     Mailers for high volume applications are preferably printed and subsequently folded in high speed devices having an input capacity of, for example, 2000 sheets. However, due to the difference in thickness abound the window aperture, a stack of 2000 sheets of mailer blanks manufactured as described above is typically about twelve inches thick around the aperture and about eight inches thick at locations remote from the aperture, such as the edge of the form being fed into the printing and folding devices. Furthermore, these sheets cannot lie flat an any bin holding them in quantities of about 2000 for feeding into a printing or folding device. 
     The various mechanisms used to feed sheets one at a time through printing and folding devices are very intolerant of curled sheets, particularly if the curl results in the corners of an individual sheet being raised or lowered with respect to the central part of the sheet. Specifically, the curl prevents individual sheets from being properly separated in the mechanisms designed to separate the sheets so that they can be fed one at a time for printing or folding. In addition, the curl causes the corners of the sheets to be caught on various obstructions along the paper feeding path of the printing and folding devices. In this way, failures to feed sheets and various types of paper jams are caused as the equipment is operated. 
     A further problem is realized by use of separately printed and inserted ID cards. Specifically, a high speed printer/folder device cannot be utilized efficiently with these cards because they will either jam a form feeder or will need to be adhered prior to the mailer being automatically folded. 
     These problems have become more serious with an increased use of non-impact printers, such as laser printers, to print the variable information on mailers, since such printers require the rapid and reliable feeding of individual sheets of paper into the printing process. 
     Attempts have been made to eliminate the need for a second transparent sheet by treating a section of the paper form so that the paper becomes transparent in a particular window area. For example, the See Thru Paper ™Window, Form #9644, manufactured by Standard Register, is described in U.S. Pat. No. 5,418,205. However, the transparency of the window area is actually only “translucent”, which can pose problems for automated mail reading devices. 
     Yet another problem in the mailing form industry is to provide a form having a return receipt post card of uniform thickness which can be conveniently printed by a single pass through a simplex, non-impact printer. Previously, confirmation of receipt of a mailed document required filling out a separate return receipt post card for a particular addressee. Typical return receipt post cards have address information or other identifying information printed on both sides of the card. Thus, not only do conventional return receipt post cards require filling out a separate form, but can also be disadvantageous because they cannot ordinarily be printed on a simplex, non-impact printer by a single pass through the printer. 
     What is needed is a mailer blank having an aperture with an open or transparent window, without the increased local thickness resulting in paper curl when significant numbers of the blanks forms are stacked. 
     What is also needed is a mailer blank which does not require separate printing and adherence of an identification card so that printing and folding can be efficiently carried out on an automated device. 
     It is also desirable to provide such a form with a return receipt post card integral therewith, wherein the return receipt post card is of uniform thickness and can have information printed on both faces of the card in a single pass through a non-impact, simplex printer. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, there is provided a mailer blank having an aperture to form a window allowing printed information to be viewed or read through this formed window. This formed window can have a transparent layer of material covering the aperture. 
     Certain features of this invention are described in the patents or applications from which this invention claims priority, namely, U.S. patent application Ser. No. 09/102,852, U.S. patent application Ser. No. 09,097,246, filed Jun. 12, 1998, U.S. Pat. No. 5,836,622, U.S. patent application Ser. No. 09/132,036, U.S. Pat. No. 5,791,553, U.S. patent application Ser. No. 09/361,660, U.S. Pat. No. 5,954,431, U.S. patent application Ser. No. 09/293,633, and U.S. Pat. No. 5,899,504. Each of these patents and applications is hereby incorporated by reference. 
     In one embodiment, the mailer blank can have a transparent layer and an opaque layer on one side of said transparent layer. The opaque layer includes an aperture covered by said transparent layer to form a window. Further, the opaque layer and transparent layer are co-extensive outward from the aperture to lateral and transverse edges of the mailer. 
     In another embodiment of the subject invention, the mailer blank comprises a die cut area forming identification card (ID card) blanks which can be efficiently printed and folded in an automated printer/folder or folder/sealer device. Advantageously, the ID cards are preferably formed contiguously in an inner layer of the form and can be easily removed therefrom by separating them from the die cut. 
     In yet another embodiment of the subject invention, the mailer blank comprises a return receipt post card which can be printed on both faces thereof by a single pass through a non-impact, simplex printer. The return receipt post card in this embodiment is configured to present all areas to be printed with variable information on a single face of the postcard, thereby allowing printing of all variable information in a single pass through the printer. The post card is provided with fold lines such that a unique folding pattern results in formation of a post card of standard size and uniform thickness, and having the variable printed information ultimately positioned at desired locations on both sides (faces) of the post card. 
     This embodiment has several additional advantages. For example, the form has the capability of being folded and duplexed to form a post card of uniform thickness meeting the requirements of the United States Postal Service (USPS). The generation of variable printed information on a single surface of the form by a single pass through a simplex, non-impact printer also guarantees that a mismatching of the variable printed information will not occur. 
     This embodiment can also be provided in several different variations. One variation provides windows having a backing or panel of transparent material which can serve as protection of the envelope contents. Preferably, the transparent panel is laminated to the inner face of the printed sheet so that any risk of jamming of the printer or the folder/sealer device is substantially reduced. An alternative variation of this embodiment of the subject invention comprises apertures or windows as cutout areas. 
     Yet another variation of this embodiment has the letter portion of the form selectively adhered, e.g., glued, around the perimeter edge only, such that the inner faces of the plies can be preprinted, thereby providing up to three printable faces of a letter in the form. Thus, the form can provide more space for text than a conventional folded form having only one face available for printing. Perforated strips formed around the perimeter, when removed by the addressee, can defeat the adherence around the perimeter edge and allow up to three page faces of the plies to be viewed with text printed thereon. 
     Each of these variations of this embodiment of the subject invention provides an advantageous mailing form on which finishing operations can be performed on a high speed folder/sealer device commonly used in the industry. For large volume mailing, this application can be especially advantageous in that no manual processing is required. Therefore, the forms can be printed on a high-speed non-impact printer, usually in excess of 100 PPM) and then finished and ready for mailing at up to about 40,000 documents per hour. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred embodiments of the subject invention are hereafter described with specific reference being made to the following Figures, in which: 
     FIG. 1 is a fragmentary, transverse elevational view of a prior art mailer blank formed in accordance with a conventional method, taken through a transparent window provided therein; 
     FIG. 2 is a fragmentary, transverse elevational view of a mailer blank formed in accordance with a first version of the present invention, taken through a transparent window provided therein; 
     FIG. 3 is a fragmentary, transverse elevational view of a mailer blank formed in accordance with a second version of the present invention, taken through a transparent window provided therein; 
     FIG. 4 is a fragmentary plan view of two paper webs and of a transparent web which are laminated together and cut to length to form the mailer blank of FIG. 2; 
     FIG. 5 is an isometric view of a mailer formed from the mailer blank of FIG. 2, shown after-printing; 
     FIG. 6 is an isometric view of the mailer of FIG. 5, shown after folding and adhesive sealing; 
     FIG. 7 is an isometric view of a mailer formed from the mailer blank of FIG. 3, shown folding and adhesive sealing; 
     FIG. 8 is a fragmentary plan view of two paper webs, and of a transparent web, which are laminated together and cut to length to form a mailer blank in accordance with a third version of the present invention; 
     FIG. 9 is an isometric view of a mailer formed from the webs of FIG. 8, shown after printing; 
     FIG. 10 is an isometric view of an alternate version of the mailer shown in FIG. 9; 
     FIG. 11 is an exploded, perspective view of an embodiment for providing an identification card in the folding mailer form according to the subject invention; 
     FIG. 11A shows a front or inner face of a front sheet for the embodiment of FIG. 11, having a substantially opaque coating patternly disposed thereon, illustrating a transparent window area; 
     FIG. 12 shows a back face of the back sheet of the embodiment shown in FIG. 11, illustrating placement of window area cutouts and positioning of printed mailing indicia; 
     FIG. 13 illustrates the embodiment of FIGS. 11 and 12 in folded configuration; 
     FIG. 14 shows separation of removable strips from the remainder of the ID card mailing form for opening the folding mailer document according to the subject invention; and 
     FIG. 15 shows unfolding of the mailer form according to the subject invention for reading a message and removing an identification card formed in the inner sheet of the mailer form; 
     FIG. 16 shows a front face of the top ply of the form according to one embodiment of the subject invention; 
     FIG. 17 shows the back face of the top ply of the form according to one embodiment of the subject invention; 
     FIG. 18 illustrates a variation of the embodiment of FIG. 16 wherein a transparent sheet is provided over the cutout window areas; 
     FIG. 19 shows an inner face of the back ply of the form according to one embodiment of the subject invention as shown in FIGS. 16-18; 
     FIG. 20 shows the back, or outer face of the back ply of the form according to one embodiment of the subject invention as shown in FIGS. 16-18; 
     FIG. 21 shows the steps in folding and sealing the mailer according to the embodiment of the subject invention as shown in FIGS. 16-20. 
    
    
     DETAILED DESCRIPTION 
     Basic differences between a mailer blank constructed according to the prior art and a mailer blank constructed according to the present invention will first be discussed, with references to FIGS. 1-3, each of which is a partial transverse cross-sectional elevation view of a respective mailer blank taken through the window aperture therein. In particular, FIG. 1 illustrates the prior art mailer blank; FIG. 2 illustrates a first embodiment of the present invention; and FIG. 3 illustrates a second embodiment of the present invention. 
     Referring first to FIG. 1, a typical prior art mailer blank  10  having an aperture window  11  conventionally placed in a sheet  12  of standard paper stock, approximately 0.004 inches in thickness. Aperture  11  is typically formed by die cutting during the manufacture of mailer blank  10 . A transparent sheet  16 , approximately 0.001 inches in thickness, is attached to cover aperture  11 , overlapping in overlap regions  18  extending along each edge of aperture  11 . The attachment of transparent sheet  16  is accomplished in overlap regions  18 , for example, through the use of an adhesive. Because the thickness of mailer blank  10  in overlap regions  18  includes both the paper thickness, the thickness of the transparent sheet, and the thickness of the adhesive, the total thickness of a stack of 2000 mailers  10  is increased from approximately eight inches to approximately twelve inches between the edges thereof and region  18 . 
     Referring to FIG. 2, a mailer blank  20  fabricated in accordance with a first embodiment of the present invention includes a transparent layer  24 , such as a transparent plastic film, laminated between an inner layer  26  of paper stock and an outer layer  28  of paper stock. The designations of “outer” and “inner” are included at this point to indicate the paper layer which will form the outer surface of an envelope, when mailer blank  20  is subsequently folded, from the paper layer which will form the inner surface of the envelope. Each paper layer  26  and  28  includes an aperture  30 , which may be formed using conventional die cutting techniques during the manufacture of mailer blank  20 . The two apertures  30  are aligned so that, when mailer blank  20  is folded into a predefined shape for mailing, visible information can be viewed through apertures  30  and transparent layer  24 . 
     Since transparent layer  24  extends to the edges  32  of mailer blank  20 , the thickness of mailer blank  20  is uniform across its entire surface. The uniform thickness is also achieved even if transparent layer  24  slightly overextends or under-extends paper stock layers  26  and  28 . It should be noted that the reduction in thickness caused by the elimination of the paper within apertures  30  does not effect the ability of a stack of mailer  20  to be stacked evenly and fed through printing and folding equipment. The thicknesses of both transparent layer  24  and paper layers  26  and  28  are determined to provide suitable stiffness to allow reliable processing through printing and folding operations, as well as to be within the regulations of the U.S. Postal Service for automatic handling of envelopes. Preferably, each of paper layers  26  and  28  has a thickness of about 0.0025 inches, while transparent layer  24  has a thickness of about 0.001 inches. 
     Alternatively, one of paper layer  26  or  28  may be eliminated in FIG. 2, in which case the, thickness of the remaining paper layer should be 0.004 inches. 
     Referring now to FIG. 3, a mailer blank  36 , fabricated in as a second embodiment of the present invention, is formed using a transparent layer  38  having a side on which an opaque layer  40  is coated. Opaque layer  40  preferably is a ultraviolet rotary screen ink material having a white or pastel color appearance, and having appropriate chemical and physical properties allowing the application thereto of inks and toners by conventional printing, processes. It should be noted that opaque layer  40  may be coated on both sides of transparent layer  38  so that mailer  20  resembles the appearance of conventional paper. 
     An aperture  42  is formed by leaving an open area in opaque layer  40 . Again, the increased thickness caused by the overlap condition of the prior art mailer blank  10  (shown in FIG. 1) does not occur, so large numbers of mailer blanks  36  may be stacked for shipping, storage, and, in hoppers for being fed individually into printing and folding devices. To provide suitable stiffness for use as a mailer, the thickness of transparent layer  38  is preferably increased into the range of 0.003 to 0.005 inches. 
     Alternately, a mailer blank of the type described with respect to FIGS. 2 or  3  may be made using a paper layer  26  laminated to a one side of transparent layer  24  or  38 , with the opposite side of transparent  24  or- 38  being coated with opaque layer  40 . In this case, the thickness of transparent layer  24  or  38  would be 0.001 inches. 
     Referring to FIGS. 2 and 3, transparent layers  24  and  38  are preferably composed of materials capable of passing through the thermal fusing station of a typical laser printer with minimal dimensional changes and curling. A suitable mate rial for these applications is polyethylene terephthalate film. The application of opaque coating  40  is facilitated by applying an antistatic or priming layer to the transparent film layers  24  or  38 . A suitable process for applying an antistatic layer is described in U.S. Pat. No. 4,371,489 to McGrail. Depending on the adhesive process used to form the laminations of FIG. 2, this type of coating may also be used to prepare transparent layer  24  for lamination. It should further be noted that the thickness of transparent layer  24  may vary between 0.0005 and 0.00125 inches, with 0.001 inches being a preferred thickness for the first embodiment, as described above with respect to FIG. 2; a preferred thickness being between about 0.003-0.005 inches for transparent layer  38  for the second embodiment, as described above with respect to FIG.  3 . 
     One preferred type of material that may be used for transparent layers  24  and  38  is Melinex 1311, one distributor of which is Plastic Suppliers, 1174 Hayes Industrial Drive, Marrietta, Ga. 35062. Melinex 1311 is a clear film with anti-static properties on both surfaces of its web. Its surface resistivity, independent of gauge, is 2×10 10  ohms/square, which overcomes the static electricity and laser corona based problems which generally prevent stacks of plastic films from being used with laser printers. Moreover, Melinex 1311 film does not suffer from unacceptable shrinkage, when passed through the high heat of the fusing stage of a laser printer. Melinex 1311 polyester film is described in more detail in U.S. Pat. No. 4,371,489 in the name of Patrick T. McGrail and entitled “Production of Antistatic Thermoplastic Films”. Additional problems encouraging the use of Melinex 1311 film are discussed in my co-pending patent application, Ser. No. 08/394,062, filed Dec. 1, 1994 and entitled “Transparent Security Pocket Compatible With Non-impact Printers”. Melinex 1311, or its equivalent without the antistatic coating, may be used as the transparent layer where paper covers substantially both sides of the transparent plastic film, such as shown in FIG.  2 . 
     Referring now to FIG. 4, a plan view is shown of two paper webs  46  and  50  and one transparent web  48 . These three webs  46 ,  48  and  50  are laminated together and cut to length to form mailer blank  20  shown in FIG.  2 . More specifically, inner paper web  46  forms inner paper layer  26 , transparent web  48  forms transparent layer  24 , and an outer paper web  50  forms outer paper layer  28 . Preferably, each paper web  46  and  50  is imprinted with a fine array of adhesive dots  52  on surface  54  to be applied against transparent web  48 . In order to avoid cluttering, a relatively course array of dots  52  is shown for illustrative purposes in FIG.  4 . Dots  52 , for example, are formed of a pressure sensitive adhesive applied using either a screen printing process or a flexographic printing process. Applying adhesive dots  52  in this manner minimizes the bulk of the adhesive, while providing a desirable type of flexibility in mailer blank  20  at a cost effective price. 
     In FIG. 4, paper layers  46  and  50  are oriented to show adhesive dots  52 , that is, both paper layers  46  and  50  are transversely displaced from transparent web  48 , and inner paper web  46  is shown as being inverted from the orientation it has when laminated to transparent web  48 . In the lamination process, outer layer  50  is applied, with pressure exerted between nip rollers (not shown), to a first side of, transparent web  48 , and inner layer  46  is applied, also with pressure exerted between nip rollers (not shown) to the side of transparent web  48  opposite the first side. Each paper web  46  and  50  includes a number of apertures  30 , which are arranged so that apertures  30  of outer web  46  individually align with the apertures  30  of inner web  50  following the lamination process. 
     Continuing to refer to FIGS. 2 and 4, the laminated web formed by laminating paper webs  46  and  50  to transparent web  48  is subsequently cut into suitable lengths, each such length to be used as a mailer blank  20 . In FIG. 4, the location of the cuts between adjacent mailer blanks is indicated by lines  54 . Conventional electronic registration or a pattern preprinted on the non-adhesive coated surface of one of the paper webs  46  or  50  may be used for determining the location of each of the apertures  30  and cuts  54 . Various perforations and/or cuts through one or both paper layers may also be made on the laminated web at appropriate locations prior to making each cut  54  to separate the web into mailer blanks  20 . As described hereafter, these additional perforations and cuts facilitate the subsequent folding and/or use of each mailer blank  20  into an envelope configuration. 
     Adhesive dots  52  are preferably arranged in a pattern which provides gaps  56 , in which adhesive dots  52  are not applied to paper webs  46  and  50 . Gaps  56 , for example, are placed along the outer edges  58  of the webs, around apertures  30 , and along the locations, indicated by lines  54 , where the web will be cut into suitable lengths. Gaps  56  prevent the outward flow of adhesive during the subsequent movement of mailer blank  20  through the heat and pressure fusing station of a laser printer which may subsequently be used to print information on mailer blank  20 . A gap width from an adjacent edge of 0.020 to 0.125 inches is preferably used for this purpose, depending on the type and quantity of adhesive used in the lamination process. Without gaps  56 , adhesive material could be squeezed out of mailer blanks  20  and accumulate in the fusing station of the printer, resulting in the contamination of the printer. A similar gap for the adhesive dots  52  may also be placed around apertures  30 . 
     Referring now to FIG. 5, an isometric view of a mailer formed from mailer blank  20  is shown in a state following the printing and lamination. The reference numerals used in FIGS. 2 and 4 are also used to indicate like features in FIG.  5 . In FIG. 5, mailer  20  includes a lower portion  64 , a central portion  66 , and an upper portion  68 . Central portion  66  may be separated from upper portion  68  by an upper fold line  70 , and from lower portion  64  by a lower fold line  72 . Fold lines  70  and  72  may be perforated or compressed lines formed during the manufacture of mailer blank  20  after the lamination, as shown and described with respect to FIG. 4, or they may merely be the fold lines resulting from the operation of folding devices into which mailer blank  20  is to be subsequently fed. 
     Both fixed information, which does not vary from one mailer  20  to another during the preparation of a batch of mailers  20 , and variable information, which does vary from one mailer  20  to another, are printed on inner paper layer  26  formed as a part of web  46 . The variable information includes at least a name and address, which is to be printed-in area  76  and oriented to be visible through aperture  30  when mailer  20  is folded along lower fold line  72  in the direction indicated by arrow  78 . Thus, the printed information should be oriented as indicated by the orientation of the letter “A”  74  in FIG.  5 . Variable information is expected to be printed using a simplex non-impact printer, such as a laser printer or an ink jet printer, whereas fixed information can be printed using the same non-impact printer or it may be preprinted during or after the manufacture of mailer  20  by normal commercial printing processes. Where the fixed and variable information are printed together, they may be printed during a single pass through the non-impact printer, as all necessary information need only be printed on inner paper layer  26 . 
     Where fixed information is preprinted, colors and patterns not readily available using a non-color, non-impact printer may be included on form  20  and printing can occur on both inner layer  26  and outer layer  28 . For example, the pre-printing may even occur on one or both of paper webs  46  and  50  (on the side opposite to the side on which adhesive dots  52  are placed) prior to applying adhesive dots  52  and laminating webs  46  and  50  to transparent web  48 , as seen in FIG.  4 . 
     Mailer  20  also includes an adhesive strip  80  extending adjacent to each lateral edge  82  and a segmented adhesive strip  84  extending adjacent an upper transverse edge  86 . In FIG. 5, adhesive strips  80  and  84  are indicated by cross-hatching. While strip  80  is shown as continuous, it is understood that it also can be broken into noncontinuous segments or otherwise patterned to control the amount of adhesive applied. Adhesive strips  80  and  84  are preferably composed of a material which can pass through the various processing stations of a non-impact printer, including the fusing station, without adverse effects. For example, the material forming adhesive strips  80  and  84  may be a microencapsulated adhesive or a remoistenable adhesive. In addition, during the manufacture of mailer  20 , suitable longitudinal perforated lines  94  may be formed along the inner boundary of adhesive strip  80 , in order to permit mailer  20  to be opened by the recipient. 
     Mailer  20  is prepared for mailing by folding first along lower fold line  72 , in the direction of arrow  78 , and then along upper fold line  70 , in the direction of arrow  88 . Pressure, or a combination of pressure and moisture, is applied to the adhesive strips  80  and  84  to seal mailer  20  in its folded condition, as seen in FIG. 6. A number of commercially available devices, well known in the art of producing mailers for distribution, may be used to facilitate both the folding operation and the activation of adhesive strips  80  and  84  through pressure or through a combination of moisture and pressure. U.S. Pat. No. 4,951,864 to Dicker describes both an adhesive system and a folding and sealing device which can be used for this purpose. 
     Referring now additionally to FIG. 6, there is shown an isometric view of mailer blank  20  after the folding and adhesive sealing thereof. Fixed information is imprinted on outer paper layer  28 , oriented as indicated by the letter “B”  90 , to provide, for example, a return address, bulk mail permit information, and opening information. Alternatively, a second window may be included in mailer blank  20  for showing a return address printed on inner paper layer  26 . 
     When mailer  20  is received, it is opened by tearing away ends  92 , which have been affixed together through the use of longitudinally extending adhesive strips  80 . Separable perforated lines  94  provided during the manufacture of mailer blank  20  facilitate opening. Next, the transversely extending adhesive strip  84  is pulled away from the portion of outer paper layer  28  to which it is attached. Mailer  20  is then opened by unfolding outward along upper fold line  70 , in the direction opposite to arrow  88 , and by folding outward along lower fold line  72 , in the direction opposite to arrow  78 . 
     Mailer  20  may include a portion  96  which is separable from the remainder of mailer  20  along a perforated tear line  98 , which also is formed during the manufacture of mailer blank  20 . For example, this separable portion  96  may be a check having the name and address of the payee printed in address field  76 . 
     Referring again to FIG. 3, a mailer blank  36 , composed of a thicker transparent plastic film layer  38  having an opaque coating  40 , may be perforated and folded as described with respect to FIGS. 5 and 6, resulting in a finished appearance as shown in FIG. 7. A number of printing processes, including the electro-photographic processes of laser printers, may be used to apply printed images to transparent plastic surfaces. Primer coats of various types, or the antistatic coating process described in U.S. Pat. No. 4,371,489 may be used to improve various aspects of this printing process. Alternately, opaque coating  40  may be applied to both sides of transparent layer  38 , with apertures aligned in each of the opaque coatings  40 , generally as shown in FIG.  2 . 
     Referring now to FIG. 7, there is shown a perspective view of a mailer  100  formed from mailer blank  36  (as shown in FIG.  3 ), having opaque coating  40  on the inner surface of the envelope and a pair of windows  42  and  102 . Specifically, window  102  is provided to facilitate printing the return address on the inner side of mailer  100  together with the addressee&#39;s address, which is seen through window  42 , as previously explained. Where the transparent plastic film is a transparent polyester film, such as Melinex 1311, fixed information, such as bulk permit information, can be preprinted on the outer surface  28  thereof. 
     Referring now to FIGS. 8 and 9, there is shown a third embodiment of the present invention, in which an integral envelope  141  is included with a mailer blank  140 . Mailer blank  140  provides integral second envelope  141 , which can be used by the recipient of mailer  140  to return a document to the original sender of mailer  140 . A typical application for mailer  140  is to send a statement in the expectation that a check will be returned in integral second envelope  141 . Generally, FIG. 8 shows a fragmentary plan view of two paper webs  112  and  116  and a transparent web  114 , which are laminated together and cut to length to form mailer blank  140 ; and FIG. 9 shows an isometric view of mailer blank  140 , formed from webs  112 ,  114  and  116 , in a condition after manufacture and printing and before folding and adhesive fastening. 
     Referring specifically to FIG. 8, inner paper web  112  is laminated to an upper surface of transparent web  114 , and outer paper web  116  is laminated to a lower surface of transparent web  114 . Inner paper web  112  subsequently forms an inner surface of mailer blank  140 , while outer paper web  116  subsequently forms an outer surface of mailer blank  140 . On the surface of outer paper web  116 , adjacent to transparent web  114 , is a repeating array pattern of adhesive dots  118 . As in FIG. 4, a relatively course array is shown for illustrative purposes. Transparent web  114  similarly has a repeating array pattern of adhesive dots  120 , together with a hollow rectangular pattern  122 , around which adhesive  126  has been applied in a continuous or more dense manner. Inner paper web  112  has a strip of release agent  124  coated thereon in a position to prevent its permanent adhesion to transverse adhesive strip  126 . Adjacent to one edge of release agent  124  on inner paper web  112  is a slit tear line  127 , which is formed after the lamination of webs  112 ,  114  and  116 . To show the pattern of a release agent  124  in FIG. 8, inner paper web  112  is inverted from the orientation it must assume when it is laminated to transparent web  114 . 
     In addition, apertures  128  are cut in each of paper webs  112  and  116  similar to apertures  30  in FIG.  4 . Further, various clear areas  130 ,  132 ,  134 , Where no adhesive dots  120  are present are placed on webs  114  and  116 . More specifically, clear area  130  is placed to be in alignment with apertures  128 , clear area  132  is placed along the longitudinal edges  133  of webs  114  and  116 , clear area  134  is placed where transverse cuts will subsequently be placed to separate individual forms to be made from laminated webs  112 ,  114  and  116 . 
     In the process of laminating webs  112 ,  114 , and  116 , apertures  128  in paper webs  112  and  116  are aligned with one another and with clear area  130  in transparent web  114 . At the same time, release agent  124  is aligned with transverse adhesive strip  126 . Paper web  112  is generally attached to transparent web  114 , through the array of adhesive dots  120 , except in clear areas  130 ,  132  and  134  and in rectangular area  136  surrounded by hollow rectangular adhesive pattern  122 . Paper web  116  is generally attached to transparent, web  114 , except for similarly clear areas  130 ,  132 , and  134 . As previously described with to FIG. 4, keeping adhesive dots  120  away from edges  133  of mailer blank  140  prevents the contamination which could otherwise result from the outward squeezing of adhesive  120  as mailer blank  140  passes through the fusing station of a laser printer. 
     A portion  138  of inner paper web  112  is not laminated directly to transparent web  114  in the area adjacent to clear area  136  and is subsequently used in the formation of integral second envelope  141 . Because portion  138  is thus not supported by direct lamination to transparent web  114 , the overall thickness of inner paper web  112  is about 0.003 to 0.004 inches, while the thickness of outer paper web  118  is preferably held at about 0.0025 inches. 
     Referring to FIGS. 8 and 9, after the lamination process, a number of perforations are cut to extend through all three layers  112 ,  114  and  116 . More specifically, a transverse perforated tear line  142 , and two longitudinal perforated tear lines  146  are placed on mailer blank  140 . In addition, transverse slit tear line  127  is cut through layer  112  only. Optionally, a perforated transverse fold line  144  may be cut, particularly if it is desired that the recipient be able to remove a portion of mailer  140  and return it in envelope  141 . The laminated weld is then cut to length, forming an upper transverse edge  148  and a lower transverse edge  150 . Variable data is printed in an address field  152 , being oriented as indicated by the letter “A”  154 . Fixed data, and additional variable data, is printed in other areas as desired. As previously described with respect to FIG. 5, an adhesive layer  156  is coated along each longitudinal edge  157 , and a series of adhesive dots  158  is placed along lower transverse edge  150 . 
     The process of using mailer  140  begins with folding mailer  140  along fold line  144  in the direction of arrow  160 , so that address field  152  becomes visible through aperture  128 . Next, mailer  140  is folded along perforated line  142 , in the direction of arrow  162 . Adhesive coatings  156  and  158  hold mailer  140  in its folded shape. As previously described with respect to FIG. 5, a number of well known, commercially available document folding devices can be used to assist in the folding and gluing of mailer  140 . 
     After receipt, the recipient opens mailer  140  by separating it along longitudinal tear lines  146  and by prying transverse adhesive dots  158  away from their attachment to outer layer  116  near fold line  144 . At this point, mailer  140  appears as seen in FIG. 9, but without the side strips below adhesive layer  156  and further without adhesive dots  158 . Next, mailer  140  is separated along tear line  127 , thereby exposing the interior pocket  143  of envelope  141  formed between inner paper layer  112  and transparent layer  114 . In FIG. 9, inner paper layer  112  is shown as partly cut away to show the interior pocket  143 . The limits of pocket  143  are defined by adhesive pattern  126 , as inner paper layer  112  in lower portion  138  is not directly attached to the adjacent clear portion  136  of transparent layer  114 . Envelope  141  may be used to return an item, such as a check and/or the portion of mailer  140  between perforated line  144  and edge  148 , to the organization originally sending mailer  140 . After envelope  141  is removed from the remainder of mailer  140  along perforated tear line  142 , a closure flap  166 , having a tear strip  168  thereon, extends between transverse tear lines  142  and  127  and separates pocket  143  from the edge of envelope  141 . At this point, the check, or other item to be returned to the sender of mailer  140 , is inserted into pocket  143  and tear strip  168  is removed, exposing adhesive  126 , as seen in FIG.  9 . On the bottom of tear strip  168 , release material  124  is also removed, as it is in a weak contact with adhesive  126 . Finally, flap  166  is folded over in the direction of arrow  170  and seals envelope  141  for mailing. 
     Referring now to FIG. 10, an alternate version  172  of mailer blank  140  is shown in which the tear strip  174  and closure flap  178  are placed along the edge  150  instead of along perforated fold line  142 . In FIG. 10, like numerical designations are used for similar components shown in FIG.  9 . The changes between mailer  140  and mailer  172  are that slit tear line  127  is replaced by slit tear line  176  defining closure flap  178  as being between line  178  and edge  150 . Adhesive dots  158  are then placed over tear strip  174  and are removed when tear strip  174  is peeled away. With this change, the adhesive dots  158  do not remain on the return envelope  141  after it is sealed. Further, adhesive  126  in FIG. 8 needs to be rotated 180 degrees and release layer  124  in FIG. 8 needs to be moved downward from the positions shown. 
     Yet another embodiment of the subject invention includes a laminated form blank for generating identification cards (ID cards) at high speeds on a laser printer in a machine foldable mailer format. These ID cards are issued to individuals by companies, e.g., health or auto insurance companies, or other organizations such as trade organizations, to provide a wallet-sized card bearing information about the individual, including, for example, an identification number. 
     One preferred embodiment is illustrated in FIGS. 11-15. Referring to FIG. 11, the subject form  200  is shown in exploded perspective view to illustrate a front or top, substantially transparent sheet  201 , and a back or bottom, substantially opaque sheet  220  which are superimposably adjoined to form the two-ply laminated mailing form. 
     The front sheet  201 , as described, is a sheet preferably rectangular and more preferably of standard paper size, provides areas for printing variable information by a non-impact printer. The front sheet is typically divided into two approximately equal halves by a fold line  202  which traverses a central longitudinal axis. The fold line can be formed by a printed line or other indicator, can be a die-cut or score line formed in the front sheet, or can be an imaginary line which is subsequently folded on an automated folding device. 
     The top half  203  of the front sheet  201  provides a message area  204  for printing information or use or interest to the addressee. The message area  204  is preferably provided toward the top right side of front sheet  201  to allow for proper positioning of other information on the left side of the bottom half  205  of front sheet  201 . 
     On the bottom half  205  of front sheet  201  is provided address areas  206  and  207 . Address area  206  is provided for printing a return address of the sender of the mailing form. Address area  207  is provided for printing address information for the addressee. This addressee information can include a bar code  208  useful for automated mail readers used by the United States Postal Service. 
     On the right side of the bottom half  205  of front sheet  201  is provided an area for printing identification card information. This identification card information area  209  can be printed so that information (shown as “ID INFO” in FIG.  11 ), e.g., name, date of birth, address, identification number, or the like, can be provided on at least one removable identification card (ID card)  210  to be retained by the addressee. The ID card  210  can be formed by making a die cut or perforation  211  around the entire ID card information area such that an ID card containing the identification information is separable from the rest of the front sheet  201 . 
     A variation of this embodiment shown in FIG. 11 illustrates formation of three ID cards  210  on a single sheet. Die-cut line  211  is made around the perimeter of each individual ID card. For efficiency, die cut line  211  is coextensive for adjacent ID cards. 
     A perforation  212  can also be provided along each perimeter edge of front sheet  210  to provide a removable strip  213  when opening the folded mailing form. 
     An adhesive  214  can be disposed on at least a portion of removable strip  213  such that the top and bottom halves of front sheet  210  are adhered together along its perimeter edge when folded at fold line  202 . Preferably, adhesive  214  is disposed along the bottom and two side edges, substantially covering the outer face of corresponding removable strips  213 , of either the top half or bottom half of front sheet  201 . In this way, the adhesive  214  matches to the corresponding outer edges of the opposing half of front sheet  201  and, along with a folded edge of the form which is created when the form is folded, provides a completely enclosed form whereas the front sheet  201  forms the inner portion of a mailer according to the subject invention. 
     The adhesive  214  used on the front face of the removable strips of front sheet  201  can be microencapsulated adhesive or remoistenable adhesive, depending on the folder/sealer device used for finishing. Microencapsulated adhesive must be of sufficient size to provide adequate wetting of the sealing edge, and must have sufficient coating so that the microencapsulates are not damaged when processed through a printer feeder. The coating must also be capable of withstanding heat of a laser printer so that premature adherence does not occur prior to folding and sealing of the mailer. 
     The front sheet  201  can comprise a plastic or polymeric material, e.g., Melinex 311 which is commercially available. Typically, the front sheet has a thickness of between about 0.003 and 0.005 inches. The front sheet can be transparent or can be printed on one face with an opaque or contrasting color for enhancing legibility of certain variable information printed thereon. However, at least one area on the front sheet is not printed with an opaque or contrasting color so that it remains transparent to provide a window for viewing address information when the form is in its folded configuration. A preferred embodiment is shown in FIG. 11A wherein front sheet  201  (shown prior to the formation of die-cuts, perforations, or printing) is provided with two transparent areas  215  and  216  for viewing address information therethrough. Most preferably, transparent window area  215  permits viewing of the return address information, and transparent window area  216  permits viewing of the addressee information, printed on the bottom left half of the front sheet. 
     In one alternative variation of this embodiment, the inner face of top sheet  201  is provided with a magnetic identification strip positioned on the back of the card area to provide a conventional credit card identifier useful in accessing an automatic teller machine (ATM) or other device capable of reading such magnetic strips. Further, the inner face of ID card area  210  can be provided with an adhesive release material, as is known in the art, to facilitate removal of an ID card from its backing sheet without any residue adhesive on the card. 
     The back, or bottom, sheet  220  is configured to substantially conform to the areas or sections provided on the front sheet. Specifically, the back sheet  220  typically comprises a standard, e.g., 8½×11 inches, size sheet of approximately equal dimension to the front sheet. One example of this embodiment is shown in FIG. 11, wherein the back sheet is divided along its central, longitudinal axis to provide a fold line  221 , conforming to the position of fold line  202  provided in front sheet  201  when the sheets are superimposed. 
     The back sheet  220  can be noncontiguous, having at least one cutout area provided therein to form a window so that address information can be seen therethrough when the form is in a folded configuration. FIG. 11 illustrates one embodiment showing two cutout areas  222  and  223  corresponding in position to the transparent window areas  215  and  216  in FIG.  11 A. Other variations of positioning and numbers of cutout areas would be readily understood according to need and in light of the description provided herein. Typically, however, this cut-out area is provided in the left side of the upper half of the back sheet for forming a conventionally positioned envelope when folded. 
     On the lower half of back sheet  220  an ID card backing area  224  is formed to provide a support web or backing sheet for the ID card or cards formed by die-cuts  211  in front sheet  201 . 
     A perforation  225  can be formed around each perimeter edge of the back sheet, substantially conforming to the superimposed position of each perforation  212  formed around the perimeter of front sheet  201 . Each perforation  225  forms a removable strip  226  which can be removed upon receipt of the mailer for opening the envelope. 
     Adhesive  227  can be coated or otherwise disposed on the inner face of back sheet  220  so that the inner face of back sheet  220  is substantially covered with said adhesive except for window areas  222  and  223 , and ID card backing area  224 . In addition, an adhesive-free area, typically about {fraction (1/16)}inches wide, can be provided along the perimeter edge of the back sheet  220 , as well as a perimeter edge of window areas  222  and  223  and ID card backing area  224  to prevent oozing of adhesive from the edges of form  200 , into window areas  222  and  223 , or onto ID card backing area  224  when the form is subjected to heat while being printed on a laser printer. 
     In the ID card backing area  224 , adhesive  226  can be provided in a striated pattern so that the ID card can be easily removed therefrom. As described, an adhesive release material can also be disposed between the ID card and ID card backing to further facilitate release of the card from the backing. 
     The back sheet  220  is formed from standard paper stock and is preferably between about 0.001 and about 0.0025 inches thick. What is important is that the total thickness of both the front and back sheet does not exceed that which will efficiently and easily feed through a typical non-impact printer feeder for high speed and high volume printing, or does not exceed U.S. Postal Service requirements when folded. 
     The back face of back sheet  220  can be preprinted with mailing indicia  230  in a position to provide standard envelope positioning of the indicia. Typically, as shown in FIG. 12, mailing indicia is printed on the same section half of the back sheet, i.e., in relation to fold line  202 , as the cutout areas  222  and  223 . This advantageously provides for forming, in a single folding step, an envelope having address information which is visible through transparent windows  222  or  223 , and mailing indicia in proper position in accordance with United States Postal Service standards. See FIG.  13 . Instructions for use can also be provided on the back face of back sheet  220 . For example, instructions for tearing off the removable strips can be provided for opening the sealed envelope. 
     In the manufacture of this embodiment of the subject invention, front sheet  201  and back sheet  220  can be preprinted with any information which is not variable or which is not necessary to be printed by a non-impact printer. For example, instructions for use, mailing indicia, certain invariable message information, or the like can be preprinted. Cut out areas in back sheet  220  can also be made. Adhesive is thus patternly disposed on the inner face of back sheet  220 . The adhesive can be coated in certain areas and striated in certain other areas, for example, in the ID card backing area. 
     Adhesive can also be patternly disposed on the outer face (which becomes the inner portion of the form in folded configuration) of front sheet  201 , particularly along removable strips  213  for sealing the envelope. 
     Front sheet  201  and back sheet  220  arc then superimposably adhered together to form a two-ply mailing form blank. The two-ply mailing form blank  200  can then be printed with variable information, e.g., addressee information, certain message information, or the like, by a non-impact printer, preferably a laser printer. 
     The printed two-ply mailing form can then be processed through an automated folder/sealer to fold the two-ply form at a predetermined fold line, e.g., fold line  202 , and sealed by activating adhesive disposed on the front face of the removable strip. 
     FIG. 14 illustrates the procedure whereby the mailer of the subject invention can be opened upon its receipt by the addressee. Specifically removable strips  213  are separated from the folded, sealed envelope or mailer, allowing the mailer to be hingeably opened along fold line  202  to expose the inner face of the mailer. See FIG.  15 . The mailer conveniently opens to reveal the message area  204  and removable ID card  210 , which can be easily removed and retained by the addressee or other appropriate receiver. 
     While the above discussion with respect to FIGS. 4 and 8, has described mailer blanks  20  and  140  formed by cutting webs made by laminating paper and transparent layers, which are subsequently cut into suitable lengths, it is understood that similar results, within the scope of the present invention, can be obtained by laminating individual sheets, already cut to the length of mailer blanks  20  and  140 , of paper and transparent layers. Similarly, the mailer blanks with respect to FIGS. 11-15 have been described as pre-cut forms, but could alternatively be formed by laminating a plastic and paper web, and then cutting to length. 
     Another embodiment of the subject invention provides a mailer having an address viewing window and a return receipt postcard integral therewith. This embodiment is preferably used in connection with an automated folder/sealer for high volume mailings. Both the mailer and return receipt post card portions can have variable information, e.g., address information, correspondence text, postage indicia, or the like, printed on a single face thereof by a single pass through a simplex, non-impact printer. The mailer and return receipt post card portions can be manipulated such that the variable information can be viewed on their respective reverse faces. Variations of this embodiment, and the steps involved in its use, are illustrated in FIGS. 16-21. Generally, this embodiment of the subject invention comprises a two-ply form comprising front and back plies wherein these plies are adhered together in certain areas to form a single, laminated form of standard size, divided by fold lines or perforations into three distinct sections. Preferably, first and second sections form the mailer portion and third section forms the return postcard portion. The material for the plies can be any material, typically a paper material, which can be printed on by a standard simplex, non-impact printer. Such materials are commercially available and are described herein. 
     The front ply is a sheet of standard size, e.g., 8½×11, 8½×14 (legal size), A 4 , or the like, divided by fold lines or perforations into first, second, and third sections of particular size. The third section must be of sufficient dimension to form a postcard of standard size and to include an additional area which receives printed information on a first side or face from a simplex, non-impact printer. This additional area can then be folded back onto itself such that address information is in proper position on the reverse side or face of the postcard portion. Typically, this third section is approximately 1½times the standard height of a postcard. The first and second sections form the balance of the sheet and are of substantially equal size to each other such that they can be folded over along a fold line provided along the mid-line between the first and second sections to be mated with one another and form the mailer portion. 
     The back ply is a sheet which is equal in width to the first ply, but is truncated in length compared to the top ply so the bottom edge of the back ply meets the bottom edge of the third section of the top ply when the top ply is folded over, thereby forming a two-ply post card. The thickness of the plies are such that the post card formed thereby meets USPS requirements. 
     FIG. 16 shows a front face of the top ply  360  of the form, having fold line AA to divide first section  361  from second section  362 . Second section  362  is defined by fold line AA and perforation BB′, and third section  363  is formed between perforation BB′ and a bottom edge of the form. First and second sections  361  and  362  of top ply  360  form an inner face of mailer portion  364 , and third section  363  forms post card portion  365 . Top ply  360  also includes perforations  366  and  367  along the entire length of its side edges, and perforation  368  along its top edge. 
     First section  361  provides areas for printing variable information, including letter return address area  369 , article number area  370 , letter addressee area  371  (including bar coded address information) and letter text area  372 . Optionally, area  410  can also be provided for printing of postage indicia, e.g., PC postage. The placement of these areas for printing variable information can be modified from the positions shown in FIG. 16 so long as they are within USPS regulations for positioning of mailing information. 
     Second section  362  provides windows  369 A,  370 A, and  371 A for showing, respectively, letter return address area  369 , article number area  370 , and letter addressee area  371  through the top ply  360  so the information can be viewed. An optional window  410 A can also be provided for viewing of postage indicia area  410 . These window areas  369 A,  370 A, and  371 A, and optional window area  410 A are formed as cutout areas in the top ply  360 . Window areas  369 A,  370 A,  371 A, and  410 A can be open cutouts or can be covered with a substantially transparent sheet (see FIG.  18  and accompanying text) to provide protection for the inner face of the mailer. It would also be understood that window areas  369 A,  370 A,  371 A and optional window area  410 A would be positioned in accordance with the respective positions of variable information areas  369 ,  370 ,  371 , and optional variable information area  410  in first section  361  so these variable information areas show through the windows. Accordingly, any variation in positions of the variable information areas  369 ,  370 ,  371 , or  410  would be reflected in complementary positional changes for the respective cutout window areas in first section  361 . 
     First and second sections  361  and  362  include perforations  366  and  367  along, and offset approximately ¼to approximately ½inch from their side edges, to form tear-away strips  366 A,  366 B,  367 A, and  367 B. At least one of tear-away strips  366 A and  366 B, and at least one of tear-away strips  367 A and  367 B have a dry adhesive, preferably encapsulated glue as described herein or in the patents or applications incorporated by reference, disposed thereon so that when opposing faces of first and second sections are folded along fold line AA, adhesive disposed thereon contacts the opposing face along the interface of tear-away strips  366 A and  366 B and along the interface of tear-away strip  367 A and  367 B to hold the first and sections together along their side edges. Dry, encapsulated adhesive can also be disposed on at least one of either tear-away strip  368 A, formed by perforation  368  along the top edge of first section  361 , or in a mating configuration on the bottom edge of second section  362 , between perforations BB and BB′, which forms tear-away strip  450 A. Tear-away strip  450 A opposes tear-away strip  368 A when first section  361  and second section  362  are folded over and mated to form the mailer portion  364  in the folded configuration of the mailer portion of the form. It would be understood that a preferred application of adhesive would be provided by an automated folder/sealer machine capable of disposing patterned adhesive at the time of folding and sealing the form. These folder/sealers are commercially available and are well known in the art. Such folder/sealers are generally capable of at least one of the following three variations: activating encapsulated adhesive in particular areas, moistening patterned moisture-activated adhesive, and patternly disposing adhesive. The form according to the subject inventions is adaptable to each of these various folder/sealers. 
     Third section  363  is adjoined at its top edge to bottom edge of section  362  to provide a section integral therewith, but is divided from second section  362  by perforation BB′. Perforation BB′ provides a fold line such that the form can be folded therealong and be mated to the back face of back ply  390  when the mailer portion is in its folded configuration. An additional perforation BB can be provided on section  362 , parallel to perforation BB′, and separated therefrom approximately the same width as tear-away strip  368 A to form tear-away strip  450 A. Return receipt postcard  377  can be later separated from the mailer portion  364  along perforation BB′ when the return receipt postcard is removed to be returned to the sender. Third section  363  also include perforations  366  and  367  continuing from first and second section  361  and  362  along the entire length of top ply  360  of the form. 
     Advantageously, however, third section  363  can also include perforations  372  and  373  spaced from the outer side edges of section  363  such that an area  374  the width of a standard post card in accordance with USPS requirements, is centrally formed in third section  363 . Area  374  formed between perforations  372  and  1373  is divided approximately one-third of its height by fold line CC to provide a first face  377  of a post card and a second area  378  which can be folded along fold line CC to form a portion of a second, reverse face of the post card. First face  377  provides an area (shown within dots) which can receive variable information printed by the single pass through a simplex, non-impact printer, to identify the addressee or contents of the mailer. Second area  378  formed opposite fold line CC from area  377  can receive return information for the return receipt post card portion. Second area  378  is preferably printed in an inverted configuration relative to the information printed of first face  377  so that when second area  378  is folded along fold line CC, it mates with the corresponding preprinted area on the opposite face of top ply  360 . For sending the mailer with a two-ply return receipt post card attached thereto, tab  372 A defined within the left-shown outer edge of third section  363  and perforation  372  and fold line CC and perforation BB′, and tab  373 A defined within the right-shown outer edge of third section  363 , perforation  373 , perforation BB′, and fold line CC, can receive encapsulated adhesive on top ply  360 . These adhesive-receiving areas on tabs  372 A and  373 A allow the tabs  372 A and  373 A to be mated and adhered to a respective corresponding section of top section  391  on back ply  390  (see FIGS.  20  and  21 ). 
     FIG. 17 shows the back face of top ply  360 , illustrating corresponding back faces of sections  361 ,  362 , and  363  formed by fold line AA and perforation BB′. Also illustrated are corresponding fold line CC formed in third section  363 , perforations  372  and  373  forming the area  374  of standard post card width, and edge perforations  366 ,  367 ,  368 , and BB forming tear-away areas  366 A,  367 A,  368 A, and  450 A, respectively. Cutout window areas  369 A,  370 A,  371 A, and optional window area  410 A are shown shifted to the opposite side of top ply  360  in order to illustrate the face as it appears when front face of top ply  360  is viewed by turning it over. Area  374 A (within dotted area on both sections  361  and  362 ) is a blank area which optionally can receive preprinted information to provide an additional page of text. This area  374 A can be preprinted if top ply  360  is mated to the back ply only along perimeter edges, i.e., along tear-away areas  366 A/ 366 B,  367 A/ 367 B, and  368 A/ 450 A, to allow the plies to be separated and viewing of their inner faces. If the form is manufactured as a laminated form wherein top ply and back ply are adhered together, this area  374 A, as well as the remaining surface of sections  361  and  362  can have permanent adhesive disposed substantially over their entire surface, or receive permanent adhesive disposed substantially over a corresponding opposing surface of the back ply or a third ply disposed between the top and back plies. Also shown are areas  379 A and  379 B (shaded) which extend from edge to edge, and equidistant from fold line CC. These areas  379 A and  379 B can receive encapsulated adhesive for folding over the bottom portion of section  363  (below fold line CC) to mate with a corresponding area of third section  363  above fold line CC. It would be understood that only one of the areas  379 A or  379 B require adhesive. This leaves area  379 C, defined above area  379 B and within perforations BB′,  372  and  373 , which can be disposed with permanent adhesive either on its own, or an opposing, mated surface. 
     As described in the other embodiments of the subject invention, it is understood that adhesive is disposed so as to leave an adhesive-free area of approximately {fraction (1/16)}inches along any edge of the form to allow for bleeding or oozing of the adhesive when plies are adhered together. 
     FIG. 18 illustrates a variation of the embodiment of the subject invention wherein a back face of top ply  360 , as illustrated in FIG. 17, includes a transparent covering  380  over cutout window areas  369 A,  370 A, and  371 A and optional cutout window  410 A provided in section  362 . FIG. 18 illustrates a preferred embodiment wherein a single sheet of transparent material is disposed between the top and back plies, extending from one side edge to the other, and having a height which is capable of covering all window areas with a single sheet. This single sheet of transparent material advantageously provides a form which is easier to manufacture and less likely to cause jamming of a simplex, non-impact printer. The transparent sheet for covering the cutout window areas can be adhered to an inner face of either ply of the form, preferably the top ply, to seal the cutout window areas from the inner face of the plies, or can be adhered to both, if the form is configured as a single, laminated form. 
     Inner and outer faces of back ply  390  are shown in FIGS. 19 and 20, respectively. As shown in FIG. 19, back ply  390  includes fold line DD to divide first section  391  and second section  392 . Second section  392 , which is of substantially identical size to first section  391  is defined by fold line DD and perforation EE′. These sections  391  and  392  positionally correspond to respective sections  361  and  362  of top ply  360 . The first and second sections  391  and  392 , shown, form an inner face of mailer portion  394 , which corresponds to mailer portion  364  of top ply  360 . Third section  393  is formed between perforation EE′ and the bottom edge of the back ply. This third section  393  forms a top portion of the back face of post card  365 . Top ply  390  also includes perforations  396  and  397  along the entire length of its side edges, perforation  398  along its top edge, and perforation EE, positionally corresponding to perforations  366 ,  367 ,  368 , and BB of top ply  360 , respectively. 
     Second section  392  provides windows  399 A,  400 A,  401 A, and optional  411 A positionally corresponding to window areas  369 A,  370 A,  371 A, and  411 A of top ply  360 , for showing, respectively, letter return address area  369 , article number area  370 , and letter addressee area  371 , and postage indicia area  410  printed on the inner face of top ply  360  so the information can be viewed. These window areas  399 A,  400 A,  401 A, and optional window area  411 A are formed as cutout areas in the bottom ply  390 . Window areas  399 A,  400 A,  401 A, and  411 A can be open cutouts or can be covered with a substantially transparent sheet (see FIG.  18  and accompanying text) to provide protection for the inner face of the mailer. 
     First and second sections  391  and  392  provide an area  399  for preprinting information (shown within dots), preferably used for preprinted letter text area in a form adhered only along its perimeter edges to provide a form having separable laminations. The placement of these areas for printing text can readily be understood to be modifiable according to the positioning of the window areas in section  392 . In a laminated variation of this embodiment, wherein top ply  360  and back ply  390  are not separable from one another such that the inner faces thereof cannot be viewed, area  399  can be substantially coated with a permanent adhesive or can be available for being mated to adhesive disposed on the inner face of top ply  360 . 
     First and second sections  391  and  392  include perforations  396  and  397  along. and offset approximately ¼, to approximately ½inch from their side edges, to form tear-away strips  396 A,  396 B,  397 A, and  397 B. An additional tear-away strip  460 A is defined by perforations EE and EE′. Preferably, tear-away strips  396 A/ 396 B,  397 A/ 397 B, and  398 A/ 460 A have an adhesive, as described herein or in the patents or applications incorporated by reference. disposed thereon so that when opposing faces of first and second sections of top ply  360  are laminated with back ply  390 , adhesive disposed thereon contacts the opposing face along the interface of tear-away strips  396 A/ 396 B,  397 A/ 397 B, and  398 A/ 460 A to hold the top and back plies together along their side edges. It would be understood that this adhesive can be alternatively disposed on corresponding sections of the inner face of top ply  360 , or can be disposed between the plies. 
     Third section  393  is adjoined at its top edge to bottom edge of section  392  at perforation EE′ provide a third section integral with second and first sections. Perforation EE provides a fold line such that the form can be folded therealong and can be later separated from the mailer portion  394  when the return receipt postcard is removed to be returned to the sender. Third section  393  also includes perforations  396  and  397  continuing from first and second section  391  ad  392  along the entire length of back ply  390  of the form. 
     The third section  393  of back ply  390  also includes perforations  402  and  403  spaced from the outer side edges of section  393  such that an area  404  is centrally formed having a width of a standard post card in accordance with USPS requirements. Third section  393  extends from perforation EE to form an area approximately one-half to about two-thirds of the height of a post card of standard size, positionally corresponding to area  379 C on top ply  360 . 
     FIG. 20 shows the back, or outer, face of back ply  390 , illustrating corresponding back faces of sections  391 ,  392 , and  393  formed by fold line DD and perforation EE′. Also illustrated are corresponding perforations  402  and  403  forming the area  404  of standard post card width, and edge perforations  396 ,  397 ,  398 , and EE forming tear-away areas  396 A,  397 A,  398 A, and  460 A, respectively. Area  404 , defined by perforations  402 ,  403 , EE′ and the bottom edge of back ply  390  forms the top portion of the back face of the return receipt post card and can be preprinted with address or other identification information, or postage indicia. An advantageous feature of this embodiment is the exact matching of bottom edge of section  363  of top ply  360  to bottom edge of section  393  of back ply  390  when section  363  is folded at fold line CC, thereby forming a contiguous flat surface of a two-ply post card having a thickness compliant with USPS requirements. Cutout window areas  399 A,  400 A,  401 A, and optional cutout window area  411 A are shown shifted to the opposite side of back ply  390  in order to illustrate the appearance of back ply  390  when it is viewed by turning over the face illustrated in FIG.  19 . Area  402 A (within dotted area) is a blank area which optionally can receive preprinted information. Area  411  provides an area for preprinting of mailing information for special services, e.g., “return receipt requested” or the like. In accordance with USPS specification, area  411  must be positioned ¼inch below the return address. Areas  412  abutting or surrounding window area  400 A are provided for preprinting of color or other indicator specific for the type of special mailing services being employed with the mailer. 
     Manufacturing the mailer according to this embodiment of the subject invention would be readily understood by those of ordinary skill in the form manufacturing art, using techniques and technologies that are readily available and commonly and currently used. Top and back plies are perforated and folded as described, and cutout window areas, including optional PC Postage window area, are formed therein, for example, by die-cuts. Permanent or encapsulated adhesive is applied in the appropriate areas and the top and back plies are adhered together either at their top and side edges, or by adhering substantially the entire inner surface of back ply to front ply as described. 
     For use of the mailer, automated folding and sealing machines, and simplex, non-impact printers standard in the industry can be employed to rapidly print, fold and seal the mailers for high-volume output. As illustrated in FIG. 21, after inner face of top ply  360  is printed with variable information, as needed (step A, shown in slightly exploded view to emphasize a two-ply laminated form), the mailer is V-folded by first folding along fold lines AA/DD (step B) to contact inner faces of sections  361  and  362  together, and adhering them together along the perimeter edges, namely, adhering tear-away strips  366 A,  367 A, and  368 A to their corresponding areas,  366 B,  367 B, and  450 A, respectively. Bottom section  378  of top ply  360  is then folded in an opposite direction along fold line CC (step C, viewed form the reverse face relative to steps A and B), termed herein a modified Z-fold, so that section  379 B is made to mate with and adhere to section  379 A on the back face of top ply  360  to form a two-ply, permanently adhered postcard. The two-ply post card is then folded along perforations BB/EE over the folded section  391 , now mated to sections  362  and  392 , and adhered along edges  366 C and  367 C and by tab areas  372 A and  373 A to form a sealed mailer having an attached return receipt post card (step D). Alternatively, the postcard portion can be formed prior to the mailer portion. 
     When the mailer is delivered, the return receipt post card can be detached from the mailer along perforations BB′/EE′,  372 / 402 , and  373 / 403  (step F) and mailed to the sender as a regular post card. The addressee of the mailer can then remove tear-away sections  166 A/ 166 B,  367 A/ 367 B and  368 A/ 450 A (step F) to defeat the adhesive disposed thereon and, as shown in step G, open the mailer for viewing of the information printed on the inner face of top ply  360 . If top ply  360  and back ply  390  are adhered only along the tear-away strips, the mailer provides the addressee with optional text viewable on the inner faces of top ply  360  and back ply  390 , as well. 
     While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.