Note: Descriptions are shown in the official language in which they were submitted.
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NEW PRESSURE SEAL FORM CONFIGURATIONS TO REDUCE PRINTER JAMS
BACKGROUND AND SUMMARY OF THE INVENTION
Mailer type business forms which utilize pressure
sensitive cohesive are becoming increasingly popular. Pressure
sensitive cohesive in its commercial form typically is a styrene-
natural rubber copolymer composition, such as shown in U.S.
patent 4,918,128 and 5,427,851. Various other forms that the
pressure sensitive cohesive may take, including commercial
formulations thereof, are disclosed in U.S. patent 5,201,464. In
the utilization of the mailer type business form intermediate
which includes a pressure cohesive, cooperating patterns of
cohesive are provided on cooperating faces of the intermediate
which are folded into contact with each other. The mailer so
formed is then run through conventional Moore SPEEDISEALER~
pressure seal equipment (as generally illustrated in U.S. patent
5,397,427) so that a pressure of about 100-200 psi is applied to
the cohesive, to provide secure adhesion of the formed panels
together. The pressure sensitive cohesive has numerous
advantages over conventional heat seal adhesive and rewettable
adhesive.
While mailer type business forms with pressure
sensitive cohesive are extremely successful, there can be a
significant problem in utilization thereof with conventional
continuous laser printers. The standard arrangement of pressure
sensitive cohesive included in the marginal portions of
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conventional mailer type business form, such as shown in U.S.
patents 5,176,739, 5,174,493, 5,314,110, is elongated strips of
cohesive
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provided in a staggered pattern on the face and the back of the form.
This standard staggered pattern was created so that stacked sheets of
the product would not block or stick together. However the provision of
the cohesive on both faces (front and back) of the sheet can result in
s flexing of the edges, particularly the long edges (the side, vertical, edges
when the sheet is in the "portrait" orientation). This flexing of the vertical
edges is called "cupping" or distortion. This distortion can be so
excessive at times that the forms cannot feed properly, jam, or cause
misfolds on some printers. The problem is compounded because many
to different paper stocks can be utilized with pressure sensitive cohesive. In
addition the cupping on the vertical edges can cause problems in post-
processing, including misfeeds, jams, and double feeds. In many post-
processing situations the vertical edge of the form is actually the lead
edge, such as when processing through a detacher, a transport station, or
is a foldeNsealer (which either V-folds, C-folds, or Z-folds the form and then
applies the necessary pressure to activate the cohesive).
According to the present invention, a mailer type business form
intermediate is provided which overcomes the cupping problem
associated with conventional pressure sensitive cohesive intermediates,
2o so that improper feeding, jamming, and misfolding of the sheet forming
the business form intermediate is substantially avoided. This is
accomplished according to the present invention by providing a particular
pattern of the pressure sensitive adhesive along the vertical edges of the
intermediate, preferably in the form of substantially rectangular spots that
2s are spaced apart a distance at least as great as the length thereof, but
provide a secure sealing action rather than merely "tacking" the form
together. While rectangular spots of pressure sensitive cohesive have
been utilized before in business form intermediates (such as shown in
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U.S. patent 5,294,041), they have not necessarily been dimensioned or
positioned to avoid the cupping problem. Rather they have typically been
staggered or spaced so that adhesive on any form length does not
contact adhesive on any adjacent form length when the continuous form
s is fan folded about longitudinal fold lines, which is an approach distinct
from that according to the invention.
According to the present invention in the preferred embodiment of
the intermediates according to the invention, the pattern which avoids the
cupping problem is the provision of a series of substantially rectangular
io spots of pressure activated adhesive each having a first dimension
parallel to the vertical edges of the intermediate of about 0.2-0.3 inches
(preferably about 0.25 inches), and a second dimension perpendicular to
the first dimension of between about 0.1-0.15 inches (typically about
0.125 inches), with the spots substantially regularly spaced from each
i5 other parallel to the vertical edges a distance of between about 1-3 times
the first dimension (preferably spaced from each other about twice the
first dimension, e.g. about 0.5 inches). Typically at least six spots (and
normally about 8-18) are provided on the first face and at least four spots
(and normally about 6-12) on the second face. Preferably all of the spots
2o within each margin portion are in a substantially straight line, and may
have uniform size and spacing, although if a few spots have a slightly
different size or spacing in order to accommodate the requirements of a
particular form (such as a spot extending across a fold line, which spot
has a first dimension of greater than .3 inches but less than about .75
2s inches), cupping problems still can be avoided under most circumstances.
According to one aspect of the present invention a mailer type
business form intermediate is provided comprising following conventional
components: A substantially quadrate sheet of paper having first and
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second faces, top and bottom edges substantially parallel to
each other, and first and second side edges substantially
perpendicular to the top and bottom edges and substantially
parallel to each other. The top and bottom edges spaced a
first distance, and the side edges spaced a second distance,
less than (or equal to) the first distance. First and
second lines of weakness formed in the sheet adjacent, but
spaced from and substantially parallel to, the first and
second side edges, respectively, to define first and second
removable side margin portions. A first fold line formed in
the sheet substantially parallel to the top and bottom
edges, and defining the sheet into panels on opposite sides
thereof. What is unique according to the present invention
is a pattern of pressure activated cohesive in each of the
side margin portions on at least the first face, the
patterns for substantially preventing cupping so that
improper feeding, jamming, and misfolding of the sheet is
substantially avoided, and wherein said pattern comprises a
series of substantially rectangular spots of pressure
activated cohesive, each spot having a first dimension
parallel to said side edges of about 0.2 - 0.3 inches, and a
second dimension parallel to said top and bottom edges of
about 0.1 - 0.15 inches, and said spots substantially
regularly spaced from each other parallel to said side edges
a distance of between about 1-3 times said first dimension.
The details of the patterns, comprising series of
substantially rectangular spots, is preferably as described
above.
Also according to the present invention for many
different embodiments (particularly C-folded or Z-folded
embodiments) a series of the spots are provided on the
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second face of the sheet in the margin portions in a same
panel as the series of spots in the first face. In this
situation the spots on the second face do not significantly
overlap the spots on the first face (that is if that they
overlap at all it is less than a tenth of an inch). Also
according to the present invention the quadrate sheet is
typically provided in continuous form format with a second
(and more) quadrate sheet substantially identical to the
first sheet except for the positioning of the spots, the
first and second sheets separated by a line of weakness
(such as a perforation line) between the second side edge of
the first sheet and the first side edge of the second sheet.
The
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spots on the first face of the second sheet are staggered with respect to
the spots on the first face of the first sheet, which facilitates feeding
especially in post processing (after passage through a continuous laser
printer), and also helps avoid the cupping problem. Separable tractor
drive margin portions may be provided adjacent and parallel to the top
and bottom edges of each sheet (the tractor drive margin portions are
typically cut off with a slitter before mailing of the mailer formed from the
intermediate).
First and second longitudinal lines of weakness are also typically
io provided substantially parallel to and adjacent the top and bottom edges
and defining a top and bottom margin in the sheets, and patterns of
pressure activated cohesive may be disposed on the top and bottom
portions. The patterns in the top and bottom margins may be
conventional strips of pressure activated cohesive rather than the spaced
spots that are provided in the side margins. The strips of cohesive may
be provided on the first face in one of the top and bottom margins, and
strips of cohesive on the second face in the other of the top and bottom
margins.
Except for intermediates which are designed to be V-folded to
2o produce the mailers, and particularly for C-fold, Z-fold, or double fold
intermediates, a second fold line (or other additional fold lines) is provided
parallel to the first fold line so that the first and second fold lines define
the sheet into at least three panels. Under some circumstances adjacent
at least one of the fold line spots may be provided on opposite sides of
2s the fold line in a side margin which are spaced from each other a distance
less than the first dimension, or at least one spot in the series in each side
margin may extend across a fold line and have a first dimension that is
longer than the spots in the series (e.g. greater than 0.3 inches but less
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than about 0.75 inches). A first series of spots may be
provided in the side margins on the first face of the first
and second panels, and a second series of spots provided in
the side margin on the second face of the second and third
panels for Z-folded constructions. The fold lines and the
series of spots are provided so that the spots of the series
align with each other when the sheet is Z-folded about the
fold lines (including eccentrically Z-folded), or C-folded,
depending upon the particular construction utilized.
According to another aspect, the invention
contemplates a mailer type business form intermediate
comprising: a substantially quadrate sheet of paper having
first and second faces, top and bottom edges substantially
parallel to each other, and first and second side edges
substantially perpendicular to said top and bottom edges and
substantially parallel to each other; said top and bottom
edges spaced a first distance, and said side edges spaced a
second distance, less than or equal to said first distance;
first and second lines of weakness formed in said sheet
adjacent, but spaced from and substantially parallel to,
said first and second side edges, respectively, to define
first and second removable side margin portions; a first
fold line formed in said sheet substantially parallel to
said top and bottom edges, and defining said sheet into
panels on opposite sides thereof; and a pattern of pressure
activated cohesive in each of said side margin portions on
each of said first and second faces, each pattern comprising
a series of substantially rectangular spots of pressure
activated cohesive disposed in a substantially straight line
closer to a said side edge of said sheet than a said line of
weakness, each spot having a first dimension parallel to
said side edges of about 0.2 - 0.3 inches, and a second
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6a
dimension parallel to said top and bottom edges of about
0.1 - 0.15 inches, and said spots substantially regularly
spaced from each other parallel to said side edges a
distance of between about two times said first dimension;
and each said series on said first face including at least
six spots, and each said series on said second face
including at least four spots.
According to another aspect, the invention
contemplates a mailer type business form intermediate
comprising: a first and second substantially quadrate sheet
of paper, the quadrate sheets of paper having first and
second faces, top and bottom edges substantially parallel to
each other, and first and second side edges substantially
perpendicular to said top and bottom edges and substantially
parallel to each other; said top and bottom edges spaced a
first distance, and said side edges spaced a second
distance, less than said first distance; first and second
lines of weakness formed in said sheet adjacent, but spaced
from and substantially parallel to, said first and second
side edges, respectively, to define first and second
removable side margin portions; a first fold line formed in
said sheet substantially parallel to said top and bottom
edges, and defining said sheet into panels on opposite sides
thereof; and a pattern of pressure activated cohesive in
each of said side margin portions on at least said first
face of the first and second quadrate sheets, the first and
second removable side margins of the first quadrate sheet
each including a plurality of vertically aligned and
regularly spaced spots of pressure activated cohesive, each
spot of the first side margin horizontally aligned with spot
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of the second side margin, the first and second removable
side margins of the second quadrate sheet each including a
plurality of vertically aligned and regularly spaced spots
of pressure activated cohesive, each spot of the first side
margin horizontally aligned with the spot of the second side
margin, the regularly spaced spots of the first side margin
of the first quadrate sheet free from overlap in a direction
of the paper feed of the regularly spaced spots of the first
side margin of the second quadrate sheet, and the regularly
spaced spots of the second side margin of the first quadrate
sheet free from overlap in a direction of the paper feed of
the regularly spaced spots of the second side margin of the
second quadrate sheet.
The invention also relates to a method of
producing imaged mailers from mailer type business form
intermediates such as described above. For example the
method may comprise the steps of: Stacking the intermediates
in a tray of a laser printer, and feeding the intermediates
one at a time from the tray through the laser printer so
that the side edges of the intermediate do not cup; imaging
at least one face of each of the intermediates; ultimately
folding the sheet about the at least one fold line to form a
mailer; and then passing each mailer through a pressure
sealer to act on the pressure cohesive to apply a sealing
pressure of at least about 100 psi to each mailer to seal
each intermediate into a mailer.
According to another method of the present
invention imaged mailers are produced from mailer type
business form intermediates by the steps of: Feeding the
intermediates, using the tractor drive holes, one at a time
through a continuous laser printer so that the side edges of
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the intermediate do not cup; imaging at least one face of
each of the intermediates; ultimately severing the tractor
drive openings from the sheets and separating the sheets
from each other, and folding each of the sheets about the at
least one fold line to form a mailer; and then passing each
mailer through a pressure sealer to act on the pressure
cohesive to
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apply a sealing pressure of at least about 100 psi to each mailer to seal
each intermediate into a mailer.
According to yet another aspect of the present invention imaged
mailers are produced from mailer type business form intermediates by the
s steps of: Feeding the intermediates one at a time through a laser printer
so that the side edges of the intermediate do not cup; imaging at least
one face of each of the intermediates; ultimately Z folding or C folding
(eccentrically or non-eccentrically) the sheet about the fold lines to form a
mailer; and then passing each mailer through a pressure sealer to act on
to the pressure cohesive to apply a sealing pressure of at least about 100
psi to each mailer to seal each intermediate into a mailer.
It is the primary object of the present invention to provide
advantageous mailer type business form intermediates having pressure
activated cohesive, and methods of producing imaged mailers in an
i5 advantageous manner from such intermediates. This and other objects of
the invention will become clear from an inspection of the detailed
description of the invention, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a schematic top plan view of an exemplary mailer
type business form intermediate according to the present invention in
combination with other like intermediates;
2s FIGURE 2 is a bottom view of the intermediates of FIGURE 1 with
the tractor drive strips removed;
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FIGURE 3 is a detail enlarged view showing the desired exemplary
pattern of pressure activated cohesive in the intermediate of FIGURES 1
and 2, with the opposite faces of the same intermediate adjacent each
other for clarity of illustration of the relative positioning of the pattern
spots;
FIGURE 4 is a top schematic perspective view showing the
intermediate of FIGURES 1 through 3 being Z-folded to form a mailer type
business form;
to
FIGURES 5 and 6 are schematic top plan and bottom plan views of
a second exemplary intermediate of a mailer type business form
according to the present invention;
is FIGURE 7 is a view like that of FIGURE 4 only showing the
intermediate of FIGURES 5 and 6 being C-folded to form a C-folded
mailer;
FIGURE 8 is a detail view showing exemplary aberrations in the
2o pattern of pressure activated cohesive that may be provided in an
intermediate according to the present.invention;
FIGURE 9 is a top plan view, with one edge curled back to show
the bottom, of another exemplary embodiment of a mailer type business
2s form intermediate according to the present invention (designed to be
eccentrically Z-folded);
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FIGURE 10 is a top plan schematic view of another exemplary
intermediate according to the present invention, this one designed to be
V-folded;
s FIGURE 11 is a top perspective schematic view showing the V-
folding of the intermediate of FIGURE 10 to produce a V-folded mailer
according to the present invention; and
FIGURE 12 is a schematic block diagram illustrating the various
io method steps that may be utilized in the practice of exemplary methods
according to the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
is FIGURES 1 through 4 illustrate an exemplary mailer type business
form intermediate 10 according to the present invention, the intermediate
being designed to be Z-folded about fold lines to produce a mailer type
business form. Except for the pattern of pressure activated cohesive, the
intermediate 10 is substantially conventional.
2o The intermediate 10 comprises a substantially quadrate sheet of
paper having a first face 11 (FIGURE 1 ) and a second face 12 (FIGURE
2) with top 13 and bottom 14 edges substantially parallel to each other,
and first and second side edges 15, 16, respectively, substantially
perpendicular to the edges 13, 14 and substantially parallel to each other.
2s The top and bottom edges 13, 14 are spaced a first distance 17 (see
FIGURE 1) while the side edges 15, 16 are spaced a second distance 18
(see FIGURE 1) less than the first distance 17. The distances 17, 18 may
vary widely depending upon the particular form being utilized. However
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the most common dimensions are about 8 1/2 inches, or about 9 1/2
inches, for the distance 18, and about 11 inches, or about 14
inches, or about 14 7/8 inches (considering the tractor drive
strips which will be described hereinafter) for the distance 17.
First and second lines of weakness 19, 20 are formed in
the sheet 10 adjacent, but spaced from and substantially parallel
to, the sides edges 15, 16, respectively, to define first and
second removable side margin portions 21, 22, respectively. A
first fold line 23 is provided substantially parallel to the
10 edges 13, 14, and defines the sheet 10 into panels on opposite
sides thereof. If the mailer to be produced from the
intermediate 10 is a V-fold mailer, then only the one fold line
23 will be provided. However more commonly C-fold (both
eccentric and non-eccentric), Z-fold (both eccentric and non-
eccentric), double fold, and like mailers are typically provided,
in which case there is at least a second fold line 24 parallel to
and spaced from the first fold line 23, so that the intermediate
10 is defined into three or more panels 25, 26, 27 (comprising
first through third panels, respectively). The intermediate 10
illustrated in FIGURES 1 through 4 is a non-eccentric Z-fold
intermediate.
The lines of weakness 19, 20 may be any suitable lines
of weakness but preferably are perforation lines. The fold lines
23, 24 may be any suitable fold lines including creases, score
lines, or the like, but preferably are perforation lines.
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10a
The pattern of the pressure activated cohesive in the
side margins 21, 22 is what is unique about the intermediate 10
illustrated in FIGURES 1 through 4. The pressure activated
cohesive per se is conventional, as shown in U.S. patents
4,918,128 and 5,427,851, and as otherwise disclosed in U.S.
patent 5,201,464. However instead of providing staggered strips,
or
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staggered spots, of the pressure activated cohesive, according to the
present invention patterns of pressure activated cohesive are provided in
the side margins 21, 22 on at least the first face 11 of the intermediate 10
for substantially preventing cupping (also known as flexing or distortion) of
s the edges 15, 16, so that improper feeding, jamming, and misfolding of
the sheet 10 is substantially avoided, both when passing through a
conventional laser printer (such as a continuous laser printer as illustrated
schematically at 29 in FIGURE 12), or when passing through conventional
post-processing equipment (such as a conventional detacher as
io illustrated schematically at 30 in FIGURE 12, and/or a conventional folder
such as illustrated schematically at 31 in FIGURE 12, a conventional
pressure sealer, such as a SPEEDISEALER~ sealer available from
Moore U.S.A. of Lake Forest, Illinois, as illustrated schematically at 32 in
FIGURE 12).
is As can be seen in FIGURE 1, but is most clear in FIGURE 3, the
desired cohesive pattern according to the preferred embodiment of the
present invention comprises a series (at least six, typically 8-18) of
substantially rectangular spots 34 in the side margin 21, and like spots 35
in the side margin 22. The spots 34, 35 are preferably aligned with each
20 other along the length 17 of the intermediate 10, and each spot has a first
dimension 36 (see FIGURE 3) parallel to the side edge 15 of about 0.2-
0.3 inches (preferably about 0.25 inches), and a second dimension 37
parallel to the edges 13, 14 of about 0.1-0.15 inches (preferably about
0.125 inches). The spots 34, 35 are spaced from each other parallel to
2s the side edges 15, 16 a distance 38. The distance 38 is small enough so
that an actual seal is provided along the edges 15, 16 rather than merely
a "tack" (that is a secure seal rather than one that may be easily
separated by sticking one's finger and implement between the spots and
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quickly separating them), but large enough so that the cupping problem is
avoided. The distance 38 is preferably between about 1-3 times the
dimension 36 and most preferably is about twice the dimension 36 (i.e.
the spacing 38 is about 0.5 inches when the preferred first dimension 36
s of 0.25 inches is used). While only the spots 34 are seen in FIGURE 3 it
is to be understood that the spots 35 are similarly -- preferably identically -
- dimensioned and spaced.
As seen clearly in FIGURES 1 through 4, preferably all of the spots
34, 35 within each margin portion 21, 22 are in a substantially straight
io line, as opposed to staggered, and preferably are immediately adjacent
the side edges 15, 16 (that is closer to the side edges 15, 16 than to the
perforation lines 19, 20).
As seen in FIGURE 2, preferably a series of spots of pressure
activated cohesive are also preferably provided on the second face 12. In
i5 FIGURE 2 (and also in FIGURE 3) the spots on the second face 12
adjacent the side edge 15 are indicated by reference numerals 34', while
those adjacent the side edge 16 are indicated by the reference numeral
35'. As most easily seen in FIGURE 3, the spots 34' (at least four are
normally provided, typically about 6-12) are substantially identical to the
2o spots 34, but are positioned so that they do not significantly overlap the
spots 34. For example, for the embodiment illustrated in FIGURE 3, the
spots 34 only overlap very slightly (less than .1 inch) the spots 34 aligned
therewith on the first face 11, but preferably there is no overlap at all.
Spacing from one face 11 to the other 12 is preferably accomplished
25 without staggering in the dimension of elongation of the edges 13, 14;
that is the spots 34' -- like the spots 34 -- are immediately adjacent the
side edge 15, being closer to the side edge 15 than the perforation line
19, and are in substantially a straight line.
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In the embodiment illustrated in FIGURES 1 through 4, since a Z-
fold mailer is provided, the spots 34, 35 are provided only in the first and
second panels 25, 26 of the first face 11, while the spots 34', 35' are
provided only in the second and third panels 26, 27 on the face 12. In
FIGURE 3 two intermediates 10 are illustrated with the top edges 13
thereof aligned and with the edges 15 thereof adjacent each other, one
showing face 11 and the other showing face 12, at the second panel 26.
The intermediate 10 may also have various other features, a
number of which are conventional. For example conventional tractor
io drive strips 40, 41 may be provided at the edges 13, 14 as illustrated in
FIGURE 1 (the tractor drive strips 40, 41 having been slit off and therefore
not visible in FIGURE 2). At some point during processing, typically after
imaging and perhaps even after folding or sealing, the strips 40, 41 are
removed, as by utilizing a conventional slitter.
Pressure activated cohesive patterns are preferably provided to
hold the mailer ultimately formed along the edges 13, 14 and/or fold lines
23, 24 rather than merely relying upon the adhesive spots 34, 34', 35, 35'.
For example in the Z-fold configuration illustrated in FIGURES 1, 2, and 4,
elongated strips of pressure activated cohesive 42 are provided adjacent
2o the top edge 13 on face 11 for cooperation with like strips 43 adjacent the
second fold line 24, also on the first face 11; while on the second face 12
(see FIGURE 2) cohesive strips 44 are provided which are adjacent the
first fold 23 and cooperate with the cohesive strips 45 adjacent the bottom
edge 14. Pertoration lines 46, 47 are parallel to and straddle the second
fold line 24, while perforation line 48 is adjacent and parallel to the top
edge 13 with the cohesive strips 42 between the edge 13 and the
perforation line 48. Similar perforation lines could be provided adjacent
the strips 44 and 45, if desired.
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FIGURE 1 shows the intermediate 10 after it has passed -- in the
direction of arrow 50 -- through a continuous laser printer (e.g. 29 in
FIGURE 12) or the like so that address information -- such as the
outgoing address 51 and/or the return address 52 -- is imaged on the
intermediate 10. For the construction illustrated in FIGURES 1 through 4,
the addresses 51, 52 are imaged on the first face 11 of the third panel 27.
Text to provide information to the addressee -- which text is illustrated
schematically at 53 in FIGURE 1 -- may be imaged either using the
continuous laser printer (29 in FIGURE 12), or can have been preprinted
1o before the intermediates 10 were supplied to the entity that will do the
ultimate address imaging, detaching, etc.
FIGURES 1 and 2 show the intermediate 10 in combination with a
second intermediate 110 which is essentially identical to the intermediate
except preferably for the positioning of the patterns of cohesive. The
i5 intermediates 10, 110 are connected to each other by a line of weakness,
such as a perforation line, 16, which will form the second side edge of the
intermediate 10, and a first side edge of the intermediate 110, when
detached (e.g. using a conventional detacher illustrated schematically at
30 in FIGURE 12). Because the intermediate 110 is substantially
2o identical to the intermediate 10 the components thereof that are the same
as those of the intermediate 10 are shown by the same reference
numeral, while those that are slightly difFerent are shown by the same
reference numeral only preceded by "1 ".
As earlier indicated, preferably the only significant difference
2s between the intermediate 110 and the intermediate 10 is the particular
positioning of the spots 134, 135, 134', 135', of pressure activated
cohesive. The spots 134 are staggered in the length dimension 17 with
respect to the spots 35, and the spots 135 staggered in the length
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dimension 17 with respect to the spots 34 (and similarly for the spots 134'
and 35', and 135' and 34'), so that there is little, and preferably no,
overlap between them in the length dimension 17. Therefore even if the
combination of intermediates as illustrated in FIGURE 1 is fanfolded
5 about the lines/edges 15, 16 there will be no significant overlap of
pressure activated cohesive spots (that is the spots 34, 135 will not
engage each other, nor will the spots 35, 134, and similarly for the spots
on the face 12 as illustrated in FIGURE 2).
FIGURES 1 and 2 show the intermediates 10, 110 as part of a
to continuous web (which may be fanfolded), the intermediates 10, 110
alternating over the entire length of the web.
FIGURE 4 illustrates Z-folding of the intermediate 10 about the fold
lines 23, 24 after detachment from the intermediate 110 (and slitting off of
the tractor drive strips 40, 41 ). It will be seen that the spots 34 on the
first
is panel 25 will align with the spots 34 on the second panel 26 while the
spots 35 on the first panel 25 align with the spots 35 on the second panel
26, and the spots 34' on the second panel 26 will align with the spots 34'
on the third panel 27 while the spots 35' on the second panel 26 align with
the spots 35' on the third panel 27. When in this configuration, then, the
2o mailer of FIGURE 4 is passed through the conventional
SPEEDISEALER~ equipment (illustrated schematically at 32 in FIGURE
12, and such as shown generally in U.S. patent 5,397,427) so that a
pressure of about 100-200 psi is applied to the cohesive (and preferably
only to the cohesive strips, not to the entire mailer) to effect secure
sealing of the panels 25-27 to form a mailer. The mailer may then be
mailed or otherwise delivered.
FIGURES 5 through 7 illustrate a second embodiment according to
the invention, this embodiment being a conventional C-fold mailer, except
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for the patterns of cohesive. In the FIGURES 5 through 7 embodiment
the same two digit reference numerals are used for like components in
the FIGURES 1 through 4 embodiment, only preceded by the numeral
..2",
s The intermediate 210 of FIGURES 5 through 7 has a series of
cohesive spots 234, 235 disposed substantially along the entire lengths of
the side edges 215, 216 as illustrated in FIGURE 5 for the face 211, while
the spots 234', 235' are provided only in the third panel 227. In this
embodiment the address indicia 251, 252 are imaged on the second face
io 212 of the second panel 226 (see FIGURE 6), while text 253 is imaged on
the face 211 of the panels 225, 226, as well as optionally on the face 211
of the panel 227 (the indicia thereon may be different, such as the bank
check or draft indicia illustrated schematically at 55 in FIGURE 5). As
seen in this embodiment when the intermediate 210 is C-folded -- as
i5 illustrated schematically in FIGURE 7 -- about the fold lines 223, 224, the
spots 234 of the second panel 226 cooperate with the spots 234 of the
third panel 227, and similarly the spots 235 of the second panel 226
cooperate with the spots 235 of the third panel 227, while the strips 242,
243 cooperate with each other; and the spots 234' on the third panel 227
2o cooperate with the spots 234 on the first panel 225, and the spots 235' on
the third panel 227 cooperate with the spots 235 on the first panel 225,
and the strips 244, 245 cooperate with each other.
FIGURE 8 shows a minor modification that may be provided
according to the invention. Rather than all of the spots 34 (or 234, 35,
2s 235, 34', 234', 35', 235') being entirely regular in dimension and spacing,
the spacings and dimensions may vary slightly at particular points in the
forms. In this embodiment structures comparable to those in FIGURE 1
are shown by the same two digit reference numeral preceded by a "3".
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For example in FIGURE 8 for an intermediate 310 at a perforation 324 a
spot of cohesive 57 is illustrated that has a first dimension (along the side
edge 315) that is slightly greater than the dimension of the spot 334 in the
first dimension, for example the first dimension of the spot 57 being
s between about .3-.75 inches, and in the embodiment illustrated in
FIGURE 8 traversing fold line 324. In some circumstances the spacing
(comparable to the spacing 38 in FIGURE 3) may be changed between
one or more spots compared to the majority of the spots in order to
properly and effectively fit the form, or to take into account where
io particular fold lines or perforation lines are located.
FIGURE 9 illustrates another intermediate 410 according to the
present invention, the components therein comparable to those in the
FIGURES 1 through 4 embodiment illustrated by the same two digit
reference numeral only preceded by a "4". The embodiment in FIGURE 9
15 is an eccentric Z-fold embodiment so that the first panel 425 has a length
dimension (along the side edges 415, 416) which is less than the lengths
of the panels 426, 427 (which are substantially the same as each other).
In this way when eccentric Z folding about the fold lines 423, 424 takes
place the spots 434 on the panels 426, 427 cooperate with each other
2o while the spots 435 on the panels 426, 427 similarly cooperate, while the
spots 435' and 434' (not shown) on the second face 412 of the panels
425, 426 cooperate. Similarly the strips 442 cooperate with the strips
443, while the strips 444, 445 cooperate.
FIGURES 10 and 11 show another embodiment of intermediate
2s 510 according to the invention. In this embodiment components
comparable to those in the FIGURE 1 embodiment are shown by the
same two digit reference numeral only preceded by a "5".
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The embodiment 510 of FIGURES 10 and 11 is a V-fold
embodiment, so that only a single fold line 523 is provided. The
intermediate 510 is shown being V-folded in FIGURE 11 so that the spots
534 in the panel 525 cooperate with the spots 534 in the panel 526, and
similarly the spots 535 in the panel 525 cooperate with the spots 535 in
the panel 526, and the strips 542 cooperate with the strips 543. In this
embodiment the address indicia 551, 552 is imaged on the face 512 of
the first panel 525, as seen in FIGURE 11.
It should also be understood that other modifications may also be
to provided according to the invention. For example eccentric C-fold
intermediates may be provided, as well as double fold intermediates, or
other multiple fold intermediates (including double Z-fold).
In the construction and utilization of all of the intermediates 10,
110, 210, 410, 510 as described above, the basic method of operation is
i5 schematically illustrated in FIGURE 12. The intermediates 10, 210, etc.
are fed -- as illustrated schematically at 60 in FIGURE 12 -- to the imaging
station 29 (e.g. a conventional continuous or sheet fed laser printer),
being fed in either a continuous format (as seen in FIGURE 1, in the
direction of the arrow 50), or in sheet format, either from a fan-folded
2o stack or individual sheets in a tray. After imaging, such as the address
information 51, 52 and perhaps text 53, on one or both faces 11, 12,
using the laser printer at station 29, if the intermediates are in continuous
format (as seen at 10, 110 in FIGURES 1 and 2) they are detached as
illustrated at 30 using a conventional detacher. Ultimately they are folded
25 and sealed, as illustrated schematically by stages 31, 32. The folding and
sealing stages 31, 32 can be incorporated in the same piece of
conventional equipment, the folding being either V-folding, C-folding, Z-
folding, or the like, and the pressure sealing at station 32 applying a
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pressure of about 100-200 psi to the cohesive spots or strips to securely
seal them together. Then the mailers so produced are mailed or
otherwise distributed as illustrated schematically at station 61 in FIGURE
12.
s It will thus be seen that according to the present invention an
exemplary mailer type business form intermediate, and method of
utilization thereof, to produce imaged mailers, have been provided which
are advantageous compared to the prior art. In the practice of the
method according to the invention cupping of the side edges (e.g. 15, 16)
io is substantially eliminated both during imaging (e.g. through a laser
printer
29) or in subsequent detaching, folding, and like operations (e.g. as
illustrated schematically at 30, 31, in FIGURE 12). This is accomplished
according to the invention without introducing any unnecessary
complications into the system, and in fact even allows slightly less
15 cohesive to be utilized than in the prior art, for each intermediate. While
the invention has been herein shown and described in what is presently
conceived to be the most practical and preferred embodiment thereof it
will be apparent to those of ordinary skill in the art that many modifications
may be made thereof within the scope of the invention, which scope is to
2o be accorded the broadest interpretation of the appended claims so as to
encompass all equivalent products and methods.
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