Patent Abstract:
A reusable envelope has a front address panel and a rear panel joined along three edges to form a pocket with an open top. A first extended sealing flap joined to the top edge of the address panel is provided with a tear strip formed by a line of perforations extending across the top edge of the envelope and through the flap. A second sealing flap is provided which is foldably connected to the top edge of the rear panel and is initially either folded and retained inside the envelope pocket or against the exterior of the rear panel for the first mailing, and is folded over and onto the first panel for the second use. The second flap has an adhesive area securing means for sealing the envelope when the flap is positioned on the address panel for a further mailing. The address panel is provided with an area is for postage indicia and, is optionally provided with a first return address area adjacent the top edge of the address panel. The address panel optionally includes a second return address area located adjacent the bottom edge of the address panel and another area for applying postage. The second sealing flap is sized to cover at least the first return address area and first postage area and, optionally, the first address area, when the second sealing flap is folded over and sealed to the address panel, and can also be pre-printed by the originator with return address and bulk mailing indicia. A single-use easy-open envelope employing the tear strip is also described.

Full Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a remailable or two-way envelope adapted to be used after its first mailing to return an enclosure, such as a payment or the like, to the original sender. 
     Remailable envelopes are well known in the art and numerous patents describe many different variations of remailable envelopes. Some examples of patents showing this type of envelope include U.S. Pat. No. 4,730,768 to Gendron; U.S. Pat. No. 5,251,810 to Kim; and U.S. Pat. No. 5,875,964 to Pham. 
     It has been found that the remailable envelopes of the prior art have not received widespread commercial acceptance by manufacturers or approval by recipients who are obliged to use them. 
     It is therefore an object of the present invention to provide a reusable envelope that can be quickly and easily opened and provides a return envelope that is easy for the recipient to use. 
     It is also an object of the invention to provide a reusable envelope that is relatively simple in construction as compared to those of the prior art, that is inexpensive to manufacture on existing production machines, and that can be used both in the manufacture of direct mail articles in which the preprinted enclosures are placed in the envelope pocket during the formation of the envelope, and also to produce finished envelopes into which the enclosures are placed subsequently by the original user. 
     It is a further purpose of the invention to provide an easy-opening envelope that permits rapid access to the contents of the envelope pocket without the possibility of damaging the enclosures. 
     SUMMARY OF INVENTION 
     The improved envelope of the present invention includes an address or front panel and a rear panel that are joined along the periphery of three edges to form an envelope pocket with an open top for receiving enclosures. A first sealing flap is formed as part of an extended flap panel that is joined to the top edge of the front address panel along a first weakened parting line, e.g., a line of perforations. The extended flap panel is folded along a transverse flap fold line that is parallel to, and spaced apart from the top edge of the address panel and is provided with a second weakened parting line, i.e., a line of perforations that is aligned with the first line of perforations when the flap panel is folded to a superposed position over the rear panel. The upper portion of the envelope between the flap fold line and the overlying perforation lines defines a tear strip. The flap fold line is spaced from the perforations a distance that is sufficient to permit the recipient to grip the tear strip for removal to open the top of the envelope. In a preferred embodiment, the area between the flap fold line and perforation lines includes a layer of adhesive joining the opposing sides of the tear strip. The adhesive can be applied as a liquid, a hot-melt composition, or as a separate laminate of polymeric material that is activated by heat, ultrasound, or the like, such materials and methods being well known in the art. The adhesive provides additional strength to the tear strip and facilitates the removal of the tear strip cleanly. The adhesive also constitutes a barrier to the undesired movement of the envelope&#39;s enclosure(s) into the tear strip area. 
     In the manufacture of the envelope of the invention, the first and second lines of perforations are formed simultaneously, as by passing the partially formed web, or sheet forming the envelope blank through a perforating wheel to provide conventional or slit perforations. In the manufacture of the envelope of this embodiment, the adhesive is also applied prior to the folding of the extended flap panel in the area that lies between the first and second lines of perforations. 
     The free end of the extended sealing flap panel and is provided with adhesive along its edge for sealing the envelope for mailing after the flap is closed over the open top of the pocket. 
     The front address panel is provided with a mailing address display area which can be a window, with or without a transparent cover. The manufacture of window envelopes is well known in the art. 
     A second sealing flap is joined along a second fold line to the top edge of the rear panel is initially folded against the rear panel either inside the pocket or on the exterior surface of the rear panel for the first use of the envelope. After the sealed envelope is opened by the first recipient&#39;s removal of the tear strip, the second sealing flap is either withdrawn from the pocket or moved from its exterior position for folding over and onto the front address panel. The second flap is also provided with securing means, such as remoistenable adhesive, for closing the open top and sealing the envelope for the second mailing. 
     In a preferred embodiment, the address panel is provided with postage indicia, which can include a bulk mailing permit and, optionally, has a first return address display area adjacent the top edge of the front panel. The upper right hand corner of the address panel is reserved for application of postage stamps or other postage indicia in accordance with government postal service requirements. 
     In a first preferred embodiment, the second sealing flap is printed with a return address display area and has an area for receiving postage or, most preferably, is provided with preprinted return postage permit indicia for postage paid by the originating party. In this embodiment, the second flap covers the originating postage indicia and return address, and, optionally, the original address display area, the second flap and has the second mailing address preprinted on the flap. 
     In another preferred embodiment, the front panel includes a second return address display area located adjacent the bottom edge of the address panel for use by the second sender and a corresponding area for the second sender to apply postage. In this embodiment the second sealing flap is sized to cover the first return address and originating postage area when the second sealing flap is folded over and sealed to the front panel. 
     In yet another embodiment of the invention, a single-use envelope of otherwise conventional construction is provided with a tear strip along one of the four edges, formed as described above, to provide for the rapid and easy-opening of the envelope. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In order that the invention may be clearly understood and readily carried into effect, preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings wherein: 
     FIG. 1 is a plan view of the front of a cut blank for an envelope constructed in accordance with one preferred embodiment of the present invention; 
     FIG. 2 is a plan view of the rear of the cut blank shown in FIG. 1; 
     FIG. 3 is a plan view of the partially formed envelope prepared from the blank of FIG. 1; 
     FIG. 4A is a cross-sectional view taken along line  4 — 4  in FIG. 3 showing one preferred embodiment; 
     FIG. 4B is a cross-sectional view taken along line  4 — 4  in FIG. 3; showing another preferred embodiment; 
     FIG. 5 is a cross-sectional view of the embodiment of FIG. 4B at a further stage in its manufacture; 
     FIG. 6 is a plan view of the front of a partially-opened sealed envelope constructed from the blank of FIG. 5; 
     FIG. 7 is a plan view of a sealed envelope constructed from the blank of FIG. 1 ready for a second mailing; 
     FIG. 8 is a plan view of the rear of a cut blank for an envelope constructed in accordance with another embodiment of the invention; 
     FIG. 9A is a plan view of the front of a sealed envelope according to another embodiment of the present invention ready for the first mailing; 
     FIG. 9B is a cross-sectional view taken along section line  9 B of FIG. 9A; 
     FIG. 10 is a plan view of the front of the envelope shown in FIG. 9 ready for a second mailing; 
     FIG. 11 is a plan view of an envelope ready for the first mailing in accordance with another embodiment of the invention; 
     FIG. 12 is a plan view of the envelope of FIG. 11 ready for the second mailing; 
     FIG. 13 is a plan view of an envelope ready for the first mailing in accordance with another embodiment of the invention; 
     FIG. 14 is a plan view of the envelope of FIG. 13 ready for the second mailing; 
     FIG. 15 is a plan view of an envelope ready for the first mailing in accordance with another embodiment of the invention; 
     FIG. 16 is a plan view of the envelope of FIG. 15 ready for the second mailing; 
     FIG. 17 is a plan view of an envelope ready for the first mailing in accordance with another embodiment of the invention; 
     FIG. 18 is a plan view of the envelope of FIG. 17 ready for the second mailing; 
     FIG. 19 is a plan view of an envelope ready for the first mailing in accordance with another embodiment of the invention; 
     FIG. 20 is a plan view of the envelope of FIG. 19 ready for the second mailing; 
     FIG. 21 is a plan view of the interior of a cut blank for an envelope in accordance with another preferred embodiment of the invention; 
     FIG. 22 is a plan view of the interior of a cut blank in accordance with another embodiment of the invention; 
     FIG. 23 is a plan view of the interior of a cut blank in accordance with another embodiment of the invention; 
     FIG. 24 is a plan view of the exterior of the blank of FIG. 23; 
     FIG. 25 is a plan view of the rear of a finished envelope produced from the blank of FIGS. 23 and 24; and 
     FIG. 26 is a plan view of the front of a finished envelope produced from the blank of FIG.  22 . 
     FIG. 27 is a plan view of the front of a finished envelope produced from the blank of FIG.  21 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A pre-cut blank  1  used to construct an envelope  10  according to the present invention is shown in FIGS. 1 and 2. As used herein, the letter “A” will refer to the exterior face and the letter “B” will refer to the interior face of the cut blank  1 . The cut blank  1  is typically formed from a web or larger sheet of suitable envelope grade material in accordance with methods well-known in the art. The blank includes a front or address panel  12  and a rear panel  14 . Panels  12  and  14  are integrally joined along intermediate fold line  16 . The panels  12  and  14  are of a similar size and generally rectangular in shape. 
     An extended flap panel  39  is joined to the top edge of front panel  12  along a first weakened parting line  42 , which in a preferred embodiment is a line of perforations, being either slit or hole perforations. Panel  39  is also provided with transverse flap fold line  41  and a second weakened parting line of perforations  46 , both of which are parallel to first perforation line  42 , the area between the perforation lines  41  and  42  defining tear strip  40 . The free end  44  of extended flap panel  39  is provided with adhesive  48  for sealing the envelope. 
     As shown in FIGS. 1 and 2, a pair of side sealing panels  18  having an adhesive area  20  on face  18 A are integrally joined to the lateral edges of address panel  14  along fold lines  22 . As will be apparent to one of ordinary skill in the art, side sealing panels  18  can be joined to panel  12 , and can be sealed to the interior or exterior of the adjacent panel. In the mass production of direct mail articles, the envelope of the invention can be produced without side sealing panels  18  by simply applying adhesive  20  to the edges of the interior of either of panels  12  or  14 . 
     As further shown in FIG. 1, a second return flap  26  is integrally joined to rear panel  14  along second fold line  28  and as shown in FIG. 2, includes an adhesive area  30 . 
     In the manufacture of the envelope of the invention, adhesive  20  is applied to side flap sealing panels  18 B and panels  18  are folded inwardly along lines  22 . The blank  1  is folded along line  16  to place rear panel  14  on front panel  12  to form the envelope pocket. A view of the front of the envelope at this stage of manufacture is shown in FIG.  3 . 
     A remoistenable adhesive  48  and preferably hot melt adhesive  43  is applied to extended flap  39 . Extended flap  39  is folded along line  41  and passed through perforating apparatus, e.g., a perforating wheel, to simultaneously form lines of perforations  42  and  46 , and, optionally, the two opposing faces of tear strip are bonded together to provide additional strength and to facilitate the clean removal of the tear strip by the recipient. 
     In this embodiment, address panel  12  is provided with an address display window which is either left open or closed by a transparent panel (not shown). As also shown in FIG. 1, front panel  12 A is provided with a return address area  52  and a corresponding original postage area  54 . In one embodiment, address panel  12 A is provided with a second return address area  56  and a corresponding second stamp area  58 . 
     As shown in cross-sectional views  4 A and  4 B, the second flap  26  can be folded into position inside the envelope pocket or flat against the exterior of rear panel  14 A. 
     The cross-sectional view of FIG. 5 shows the envelope  10  ready to mail with enclosure  2  in the envelope pocket following insertion through the open top. When the enclosure  2  is inserted into envelope  10 , the “TO” address is properly positioned in the display panel  50  of the window envelope. The envelope  10  is now ready for mailing. 
     To open the envelope  10 , the tear strip  40  is removed along the perforation lines  42  and  46  as shown in FIG.  6 . The tear strip  40 , having been folded along fold line  41  and preferably reinforced by the bonding of adhesive areas  43  and  45 , provides a convenient and easy way to remove the tear strip for opening the envelope. Upon removal of the tear strip  40 , the entire top of the envelope pocket is open across the full width of the envelope and the contents of the envelope can be easily inspected and removed. 
     In order to re-use the envelope of this embodiment, the following steps are taken: 
     (a) If materials are to be returned to the sender, the recipient inserts materials into the open envelope, again with the proper “TO” address properly positioned in the display window  50 . 
     (b) The second flap panel  26  is then moved from its position adjacent rear panel  14  and folded along line  28  over and onto address panel  12 A, as shown in FIG.  7 . The distance between fold line  28  and the distal or free end of return flap panel  26  is predetermined to have a length sufficient to cover the postage area at  54  and the return address area  52  for the second use. 
     (c) The adhesive  30  is then used to seal the envelope  10  with return flap face  26 B adhesively secured to address panel face  12 A. 
     (d) The recipient completes the return address at the address area  56  and places the proper postage at area  58 . Alternatively, the original sender can provide the recipient&#39;s return address by computer-directed printing means at the time that the envelope blank and its enclosures are printed, die-cut and assembled. Return postage mailing indicia  58  can also be preprinted on return flap  26  by the originator. 
     FIG. 7 shows sealed envelope  10  ready for the second mailing by the recipient as preaddressed and postage paid by the original sender. 
     FIG. 8 illustrates another embodiment of the invention in which the blank  1 ′ is laid out to provide a second tear strip  40 ′ defined by perforation lines  42 ′ and  46 ′ and intermediate fold line  41 ′. The second tear strip  40 ′ is removed by the second recipient to open the envelope pocket and thereby gain access to its enclosures. Assembly of this embodiment is similar to that described above, and as will be apparent to one of ordinary skill in the art, the application of adhesive to tear strips  40  and  40 ′ is desirably accomplished simultaneously prior to folding of the blank  1 ′. Likewise, the perforation of the folded tear strips along lines  42 ,  46  and  42 ′,  46 ′ is preferably accomplished simultaneously by a pair of appropriately spaced perforation wheels on automated equipment. 
     FIGS. 9 and 10 illustrate a further embodiment of the invention ready for use in the second mailing where the second sealing flap is extended to cover the original mailing address and is preprinted with the second mailing address, mailing indicia and the original recipient&#39;s return address. In this embodiment, the second flap  26  can be provided with one or more transverse folds to make it more compact and easier to withdraw from the envelope pocket. In this embodiment, as illustrated in FIGS. 9A and 9B, the envelope is ready for the first mailing and the tear strip  40  extends across the top of the sealed envelope above the fold line  28  between the rear panel  14  and the second flap  26 , the flap being shown accordion folded in position during mailing. As shown in FIG. 10, when second flap  26  is extended for the second mailing and sealed in position on panel  12 , it completely covers the first mailing address, and preferably is provided with the second recipient&#39;s mailing address, postage and first recipient&#39;s return address area, which can be blank or completed during the original printing. 
     FIGS. 11-20 illustrate further embodiments of envelopes of varying formats constructed in accordance with the invention. Additional variations will be apparent to those of ordinary skill in the art based on the descriptions provided. In each of FIGS. 11-18, the envelopes are depicted with window mailing address display areas, but it will be understood that printed addresses can be employed. The elements  12 A and  14 A correspond to those used above in describing FIGS. 1-7. Flap elements shown in dotted lines depict the flap positioned on the reverse side of the envelope. Dashed lines represent perforations. 
     With reference to FIG. 11, the first address display area is positioned on rear panel  14  and the first sealing flap is provided with first return mailing address and postage indicia, the first sealing flap being removable by the recipient. As illustrated, the sealing flap is provided with weakened parting line  140 , i.e., perforations, parallel to the free edge of the first sealing flap. After removal of the tear strip, the first recipient removes the upper portion of the sealing flap to expose the second return address area and postage indicia printed on panel  14 A. 
     Alternatively, a releasable adhesive or small adhesive spots can be employed on first sealing flap, so that the entire portion of the remaining flap can be removed following removal of the tear strip to open the envelope. FIG. 12 shows the envelope panel  14 A of FIG. 11 ready for the second mailing. 
     FIG. 13 illustrates the embodiment where the front panel  12 A is arranged for the first mailing and employs a window for the mailing address display. 
     FIG. 14 illustrates the reusable envelope embodiment of FIG. 13 following removal of the tear strip and placement of the second sealing flap in position on the front panel above the window. In this embodiment, the second return address and postal indicia are preprinted on the second sealing flap and cover those elements as they appeared in FIG.  13 . 
     The embodiment of FIG. 15 illustrates the first mailing address display area on the rear panel with the first return address and postal indicia on the first sealing flap; following removal of the tear strip and positioning of the second sealing flap with postage and return address indicia on front panel  12 A, as shown in FIG. 16, the envelope is ready for its second mailing. 
     FIGS. 17 and 18 illustrate a further embodiment where an envelope constructed in accordance with the invention. The envelope is preprinted with return address and postage indicia on front panel  12 A as shown in FIG. 17 for the first mailing. Following removal of the tear strip, the second sealing flap (shown in dotted lines) is sealed in place for the second mailing, and as shown in FIG. 18, the rear panel is provided with a return address area and postage indicia. 
     In the embodiment of FIGS. 19 and 20, both the first sealing flap and second sealing flap are large enough to be provided with the respective mailing address display areas, as well as the return address and postal indicia. As illustrated in FIG. 19, the first mailing flap also includes a line of perforations to permit removal of the upper portion of the flap following separation of the tear strip from the envelope. As shown in FIG. 20, following removal of the first sealing flap, the second sealing flap is extended into position over the envelope front panel, and being preprinted with the required indicia, is ready for mailing. 
     A second embodiment of the present invention is shown in FIGS. 21-27. In this embodiment, an envelope is constructed from a blank of 100 envelope grade material as shown in FIG.  21  and has a front panel  102  and a rear panel  104  joined to panel  102  along first fold line  106 . Front panel  102  is further provided with a perforation line  108  which is positioned parallel with fold line  106  and spaced apart therefrom. Rear panel  104  is provided with a perforation line  110  which is positioned parallel to fold line  106  and spaced apart therefrom. An adhesive  112  is provided on panel  102  between fold line  106  and perforation line  108 . An adhesive area  114  is provided between fold line  106  and perforation line  110  as shown in FIG.  21 . The area between perforation lines  108  and  110  defines a tear strip  115 . In the embodiment illustrated in FIG. 21, adhesive  112  is also applied along the interior face of either of panels  102  or  104  prior to folding along line  106 . The adhesive is maintained within the bounds of transverse lines  108  and  110  which correspond to subsequently provided perforation lines as will be described in more detail below. 
     A conventional sealing flap  116  is joined to front panel  102  along second fold line  118 . Sealing flap  116  is provided with a re-moistenable adhesive material  120  on its surface facing rear panel  104  in the folded position. The exterior of front panel  102  includes a conventional address area  124  and a stamp area  126 . The blank is optionally provided with side sealing flaps  130 , one face of which is provided with adhesive. 
     To construct the envelope, side flaps  130  are provided with adhesive and folded inwardly; rear panel  104  is folded along first fold line  106  into superposed position on front panel  102  which also makes sealing contact with flaps  130 . Sealing flap  116  is adapted for folding downwardly on rear panel  104 . The adhesive areas  112  and  114  are, in a preferred embodiment, adhesively joined with liquid glue, hot melt or other form of adhesive. The application of adhesive along this narrow, lower band of the envelope serves to strengthen the tear strip  115  and to insure that the lower tear strip portion can be more easily removed along the parting line of perforations. The completed envelope  100  is shown in FIG.  27  and is similar in appearance to that shown ready for mailing in FIG.  2 G. To open envelope  100  the tear strip  115  is torn along perforation lines  108  and  110 . 
     In the production of direct mail articles in accordance with the invention, side flaps  130  can be eliminated and the opposing side edges of panels  102 ,  104  can be joined by adhesive in order to simplify production. 
     In an alternative preferred embodiment illustrated in FIGS. 22 and 26, a series of paper crimps are incorporated mechanically into the tear strip after folding along line  106 . As used herein, the term “crimping” or “crimps” means an indentation or partial peroration applied to mate or temporarily join a pair of paper panels. The crimping is accomplished by a crimping wheel or similar device. The crimping is positioned adjacent to, or along the same transverse line as the perforations. The formation of the crimps resists a laterally applied force. As will be understood by one of ordinary skill in the art, a s plurality of spaced crimps will prevent the enclosures placed or formed in the envelope on one side of this transverse crimp line from moving into the adjacent tear strip portion of the envelope. With reference to FIG. 22, it will also be understood that the crimp areas  140  are indicated in the extended blank for purposes of illustration only, since the crimps can only be completed after the paper has been folded into superimposed position. Thus, the crimping is completed after adhesive is optionally applied in the area defining the tear strip  115  and the flap is folded to bond the sides together and the superposed sides are pressed between the opposing faces of the crimping apparatus. 
     In the production of the envelopes shown in FIGS. 21-27, it is also preferable to form the perforations after the envelope front and rear panels are glued and folded in superimposed position so that the perforations are aligned to thereby insure an even and clean tear line. 
     A further embodiment is illustrated in FIGS. 23-25 where the easy-open tear strip is positioned along one side of the envelope. With reference to FIG. 23, the rear panel is provided with tear strip defined by parting lines  108  and  110  positioned between a lateral edge and side sealing flap  130 , the tear strip being bisected by fold line  106  into sections  132  and  134 . As shown in the embodiment of FIG. 23, a plurality of adhesive areas  121  are provided on the interior surface of tear strip  115  to join sections  132  and  134  after folding along line  106 . With reference to FIG. 24, the exterior of the blank  101  shows adhesive  120  applied to the edges of side sealing flaps  130 , and the front of the envelope provided with the conventional mailing indicia. It is to be noted from FIGS. 23 and 24 that the tear strip  115  extends laterally from the edge of the front and rear envelope panels, and as best shown in FIG. 25, from the body of the completed envelope, including the folded top sealing flap  116 . 
     The manufacture of this embodiment is similar to those described previously, with the exception that the side sealing flap  130  adjacent tear strip is folded into position at the same time sealing flap sections are folded along line  106  to bond the interior faces together to form the reinforced tear strip  115 . The front panel  102  is then folded down to contact the adhesive areas  120  on folded side sealing flaps  130  to form the envelope pocket. The envelope is then passed through perforations, means to form perforation lines  108 ,  110 . 
     As noted in the embodiment described above, the adhesive areas  121 , even though applied in a non-continuous manner, comprise a barrier to the undesired movement of the envelope enclosure(s) into the region of the tear strips. 
     In a further preferred embodiment of this aspect of the invention (not illustrated) the tear strip is provided with a row crimps immediately adjacent perforation lines  108 ,  110 . In this embodiment, the line of crimps define a barrier to the movement of the enclosures in the envelope into the tear strip area defined by the perforations, thereby precluding any damage to the enclosures when the tear strip is removed by the recipient, and the adhesive areas  112  and  114  can be optionally eliminated. Thus, it would be understood by those familiar with the art, the crimps can be incorporated and made coincident with the perforation line. Although optional, it is also desirable in this embodiment to include reinforcing adhesive, e.g., hot melt adhesive, along the interior surfaces to bond the opposing sides of the tear strip to add additional strength and thereby facilitate its clean removal. 
     While the fundamental novel features of the invention have been shown and described, it should be understood that various substitutions, modifications and variations may be made by those skilled in the art, without departing from the spirit or scope of the invention. Accordingly, all such modifications or variations are included in the scope of the invention as defined by the claims that follow.

Technology Classification (CPC): 1