Abstract:
A method of automatically forming a mailing envelope includes forming an envelope blank from a web of paper and forming a window in the envelope blank. The window defines a window edge in the envelope blank. The method includes adhering a transparent window patch to the window, the adhering operating to adhere the complete window edge to the window patch.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a non-provisional application and claims the benefit of U.S. Provisional Application No. 60/668,748, filed Apr. 5, 2005, the complete disclosure of which is herein incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to envelopes, and more specifically, to improved windowed envelopes and methods of making them.  
         [0003]     Windowed envelopes are not new, however, many problems can occur with existing windowed envelopes. For example, some envelopes have open windows with edges that can catch on mail processing equipment. When the open window edges catch on the mail processing equipment, the envelopes may tear or be deformed, further hindering the mail processing and delivery process. Some windowed envelopes have a transparent material placed over the window opening. Typically, this material is coupled to the inside of the envelope. However, current window gluing techniques still permit the edge of the envelope window to catch on mail processing equipment. This is due in part to the manner in which the window is glued to the opening in the envelope. Further, the shape of the window itself may have sharp edges that can catch on mail processing equipment and/or on adjacent envelopes, again further complicating the mail processing and delivery processes. Improvements are desired.  
       BRIEF SUMMARY OF THE INVENTION  
       [0004]     The present invention relates generally to envelopes, and more specifically, to improved windowed envelopes and methods of making same. In one embodiment, a method of automatically forming a mailing envelope includes forming an envelope blank from a web of paper and forming a window in the envelope blank. The window defines a window edge in the envelope blank. The method includes adhering a transparent window patch to the window, the adhering operating to adhere the complete window edge to the window patch.  
         [0005]     In other embodiments, the method further includes folding and adhering the envelope blank to define an envelope having an opening adapted to receive an insert; forming a taggant on the envelope blank, with the taggant adapted to be read by an optical scanning device; and/or inserting a mailing insert into the envelope with the insert having a bar code which is viewable through the window patch when the insert is disposed in the envelope.  
         [0006]     In other embodiments, the window includes a step shape on a first side and a sloped shape on an opposing side; an optical scanning device is further adapted to read a bar code through the window patch from an insert in the envelope; and/or reading of the bar code is triggered by the reading of the taggant. The bar code may include at least a customer name and address, at least a customer account number, or the like.  
         [0007]     The present invention further provides mailing envelopes. In one embodiment, the mailing envelope includes a generally rectangular front panel having an outer surface and an inner surface. The front panel has a window formed therethrough, with the window defining a front panel interior edge. A transparent window patch is coupled to the inner surface of the front panel so that the front panel interior edge is completely coupled to the window patch.  
         [0008]     In other embodiments, the front panel interior edge includes a plurality of generally straight edge sections coupled together using curved edge sections so that the interior edge is generally devoid of sharp-angled edge intersections between adjacent straight edge sections. In some aspects, the front panel interior edge is generally devoid of right angle edge sections; the transparent window patch is coupled to the inner surface with a glue; the transparent window patch is coupled to the inner surface with a gummed front panel surface portion; the transparent window patch comprises cellophane; the window comprises a non-symmetrical shape; the front panel further includes a taggant; and/or the taggant conforms to USPS standards for certified mail.  
         [0009]     The present invention further includes a die adapted to form a mailing envelope blank, and/or for forming a cut-out or window in the blank, for forming a mailing envelope as provided in the various embodiments herein.  
         [0010]     The present invention further includes methods of processing a mailing envelope. One such method includes providing a mailing envelope, and passing the mailing envelope through a scanner, wherein the scanner is adapted to read a piece of data from the envelope front panel without engaging the front panel interior edge.  
         [0011]     Other objects, features and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  depicts an envelope blank which, when folded and adhered, forms an envelope according to an embodiment of the present invention;  
         [0013]      FIG. 2  depicts an example insert for insertion into the envelope of  FIG. 1 ; and  
         [0014]      FIG. 3  depicts example dies used for forming envelopes according to embodiments of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0015]     Inventors of the present invention send and process large numbers of mailings. In some embodiments, these mailings, which may involve notices for foreclosure on real estate, are sent using the United States Postal Service (USPS) Certified Mail. Due to the large number of mailings, the inventors began using a windowed envelope through which an optical scanner can read a bar code printed on the statement inside the envelope. The bar code contains information on the customer receiving the mailing. This information may include, without limitation, a customer name, a customer address, a customer account or loan number, and the like.  
         [0016]     One advantage of this type of envelope is that by retrieving information on the customers by reading the bar codes, certified mail may be sent without having to fill out certified mail cards at the post office for each envelope. Instead, the information is logged and tracked at a third party mail processing location. Cost savings can be considerable compared to the amount the USPS would otherwise charge if the mailings required hand written green cards associated with each certified mail envelope.  
         [0017]     However, as noted above, windowed envelopes can be problematic. First, the edge of the envelope cut-out window can catch on the mail processing and/or optical scanning equipment. This problem may occur whether or not the window has a patch or transparent material in its place. In prior processing runs, as many as twenty percent (20%) of the envelopes would catch, and, when processing 2,000 to 5,000 envelopes at a time, this caused considerable downtime to refeed the envelopes by hand. Further, some envelopes tore when caught. If this happened, the entire envelope and its contents would have to be reprinted and/or repackaged.  
         [0018]     Improved envelopes and envelope manufacturing procedures were developed for the present invention. In one embodiment, manufacturing of the envelope operates to adhere the window patch all the way to the edge of the envelope cut-out window. In some embodiments, the window patch comprises cellophane, or other transparent materials.  
         [0019]      FIG. 1  depicts an envelope blank  100  that is formed from a web or sheet of paper. In one embodiment, the outer edges  108  of the envelope blank are formed simultaneously with the formation of a window  104  or cut-out in the blank. When folded, the cut-out defines the envelope window  104 , and is positioned to be generally in the center of the envelope  100  in some embodiments. As shown in  FIG. 1 , in one embodiment, the cutout  104  has an irregular or non-symmetrical shape. In the embodiment shown, the left hand side of the window  104  (when viewed from the front of the envelope) includes a stair step shape  112 . The right hand side of the window has an angled or sloped shape  116 .  
         [0020]     The lower right hand corner  120  of the envelope window  104 , on the front of the envelope  100 , was further rounded compared to prior envelopes. In this manner, the corner  120  of the envelope window  104 , which previously tended to get caught on the optical scanner, is smoother to help avoid catching. The additional rounding operates to reduce the likelihood the envelope will catch, and thus the envelope proceeds smoothly through the optical scanning or mail processing equipment.  
         [0021]     Once the envelope blank with the cut-out is formed, a window patch is adhered to the envelope over the cut-out. In one embodiment, the window patch is larger in size than the window cut-out so that it can adhere to the inside surface of the envelope and cover the cut-out. In a preferred embodiment, glue, gummed surfaces, or some other adhesive is applied to the reverse side of the envelope blank in a manner such that the edges of the cut-out window adhere to the window patch when the window patch and adhesive envelope surface are pressed together. In this manner, the edge of the window cut-out is completely affixed to the transparent window patch. As a result, the edges of the window cut-out will not catch on mail processing or optical scanning equipment.  
         [0022]      FIG. 2  depicts an example insert  200  for insertion into the envelope formed from the envelope blank of  FIG. 1 . In a preferred embodiment the bar code  204  is positioned on the insert  200  such that when the insert  200  is folded and inserted into the envelope  100 , the bar code  204  shows through the window cut-out  104  in the envelope  100 . In one embodiment, an optical scanner or bar code reader operates to read the bar code  204  on the insert  200 . In a particular embodiment, the optical scanner is triggered by a taggant  128  on the front of the envelope positioned just above the window  104 . The taggant  128 , which in some embodiments is readable under ultraviolet light, is positioned on the envelope  100  to trigger the optical scan equipment to begin reading the bar code through the window. In one embodiment, the taggant  128  corresponds to U.S. Postal Service specifications. In some embodiments, envelopes  100  further include a green certified mail rectangle  124  at the upper edge of the envelope front surface, which is of sufficient size and shape to correspond with U.S. Postal Service requirements. In some embodiments, the taggant  128  is a yellow, generally rectangular taggant to the right of the green certified mail bar.  
         [0023]     In one embodiment, the present invention further provides an optical scan system in cooperation with software that operates to read the bar codes from the envelope inserts. The system may include, without limitation, the optical scanner or bar code reader, a controller such as a microprocessor, a memory for maintaining system software and/or a database, and the like. The system may further include mail sorting equipment, automatic mail feeders, and the like.  
         [0024]     The software, in reading the bar codes, creates a table or listing of customer names, account numbers, or the like, for customers who are receiving the mailed inserts. In this manner, a series of hundreds or even thousands of envelopes may have their bar codes scanned, with a table of the customers&#39; names, addresses, account numbers, loan numbers, or the like being maintained in the system for the particular mailing. The system maintains a record of the recipients of foreclosure notices or other important pieces of mail.  
         [0025]      FIG. 3  depicts exemplary dies  300  used to form the envelopes  100  according to the present invention. As shown, the dies, or at least a portion thereof, correspond generally to the desired shape of the cutout window.  
         [0026]     In a method of manufacture according to the present invention, a guide is used to cut the overall shape of the sheet or web of paper that will be folded and glued into the envelope. In some embodiments, this cutting occurs simultaneously with the cutting of the window or hole in the sheet to accommodate a window patch. Once the overall envelope shape and window are cut, the appropriate cellophane or other window patch piece is applied. The two components may be combined using glue, a gummed surface, other adhesives or the like. Again, one improvement involves the use of glue or other adhesive so that the edge of the paper cut-out receiving the window patch is glued to the patch. The envelope is then folded and glued so that it can receive and hold inserts to be mailed. A flap is provided with glue or other adhesive that can be used to seal the envelope once it has received its contents. In some embodiments, the flap includes a gummed surface under a peel off strip. When the envelope is to be sealed, the strip is removed and the gummed surface is pressed to the back of the envelope to seal the opening shut.  
         [0027]     The invention has now been described in detail. However, it will be appreciated that the invention may be carried out in ways other than those illustrated in the aforesaid discussion, and that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the scope of this invention is not intended to be limited by those specific examples, but rather is to be accorded in the scope represented in the following claims.