Note: Descriptions are shown in the official language in which they were submitted.
CA 02549970 2006-06-13
TWO-WAY POSTAL MAILING ASSEMBLY
Cross-Reference to Related Applications
[0001] This application is a continuation-in-part of Application Serial No.
10/912,990, which claims the benefit of U.S. Provisional Application No.
60/525,328
filed on November 26, 2003, the disclosure of each of which is hereby
incorporated by
reference herein in its entirety.
Field of the Invention
j0002] The invention relates to mailers and, in particular, to mailers that
are
suitable for securing and protecting articles, such as stress-sensitive or
frangible articles,
for safe processing by automated processing equipment.
Background of the Invention
[0003] The constructions of mailpieces and envelopes must conform to specified
size and flexibility requirements. Postal services, like the United States
Postal Service,
sort large volumes of mail with high-speed automated processing equipment
having pairs
of vertical moving belts arranged in a network to grip and serially transport
individual
mailpieces at a speed of up to 40,000 pieces an hour. The moving belts convey
the
mailpieces, which are oriented vertically, at a linear velocity approaching
500 to 600 feet
CA 02549970 2006-06-13
per minute. Each mailpiece is oriented in a vertical plane such that an edge
portion of the
mailpiece is gripped between the moving belts. An optical scanner provided
adjacent to
the moving belts identifies a destination address for each mailpiece.
Mailpieces are sorted
according to the destination address and routed by the network of moving belts
into
assorted bins or stackers.
[0004] Changes in direction of transported letter mail in automated processing
equipment are accommodated by providing a pulley, roller or drum over which
the
moving belts are trained at the point where the direction change is to occur.
For example,
if the mailpiece is moving linearly in a horizontal direction and it is
desired to effect a
directional change to a different horizontal direction, a drum mounted for
rotation about a
vertical axis is placed at the change-of direction point in the path of travel
of the opposed
belts between which the mailpiece is gripped for transport. As the belts move
about the
rotating drum, the mailpiece travels through a curved path conforming to the
drum
periphery and emerges traveling between the moving belts in a new horizontal
direction.
[0005] Breakable, frangible or stress-sensitive articles, such as compact
disks or
mini-compact disks must be packaged inside a mailer. Letter-size mailers
should comply
with postal regulations, such as size requirements and address positioning,
while
protecting the stress-sensitive article from damage during sorting by the
automated
processing equipment. Moreover, postal regulations would require the mailer to
be
flexible enough to be bent and routed about the circumference of cylindrical
pulleys,
rollers and drums of the type used in automated processing systems at
locations where
directional changes occur in the travel path of the belts.
[0006] Conventional mailers would expose stress-sensitive articles to a
significant
risk of damage as the mailer is bent about the circumference of the
cylindrical roller or
drum. As the mailer is conveyed about the exterior of the pulley, roller or
drum, the
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stress-sensitive article must curve or bow and will experience a state of
tension due to the
flexure that can damage or even break the article. Thus, because of this and
other
significant shortcomings, conventional letter-sized mailers do not adequately
safeguard
stress-sensitive articles when handled by automated processing equipment of
the type
used by the United States Postal Service.
[0007] If the dimensions of the mailer exceed a maximum dimension (e.g.,
oversized) as governed by postal regulations or does meet the flexibility
requirements for
letter sorting equipment, the United States Postal Service does not treat the
mailer as a
letter. Instead, the mailer is handled as a non-letter or flat by automated
equipment that
does not require routing about the exterior of a drum. Most mass mailings,
however, are
of pre-sorted, letter-sized mailers that are less expensive to mail.
[0008] Accordingly, there is a need for mailers and mailer assemblies for
articles
that can be handled by automated letter-sized processing equipment and that
are fully
compliant with postal regulations while simultaneously protecting the article
from
damage during processing.
Summary of the Invention
[0009] The invention provides mailers configured to carry an article such that
the
mailer can be bent and transported in automated processing equipment with the
article
lifted out of contact or substantially out of contact with the belts, drums
and other
components of the processing equipment. In particular, the invention provides
mailers for
articles, such as stress-sensitive or frangible articles that are readily or
easily damaged by
stress, configured such that the mailer can be bent and transported in
automated
processing equipment without causing stress-related damage to the article. The
invention
also provides mailers for articles that positions the article such that the
belts of the
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automated processing equipment do not contact the area of the mailer
containing the
article or, alternatively, does not contact the area of the mailer overlying
more than half of
the article. The invention further provides mailers for articles that can
ensure damage-
free processing by automated processing equipment of the postal service while
securing
the article during transit from a sender to a recipient.
[00010] In accordance with an embodiment of the invention, an assembly for
mailing an article comprises an envelope and a mailer adapted to be inserted
into the
envelope. The mailer includes a first panel, a second panel joined to the
first panel to
define a first edge and a second edge, a pocket between the first and second
panels, an
access opening along a portion of the second edge for accessing the pocket to
insert and
remove the article, and a flap attached to the second edge and movable for
closing the
access opening to the pocket. The mailer further includes a false bottom
adapted to space
the pocket from the first edge by an amount sufficient to prevent damage to
the article
when the article is positioned in the pocket and the mailer and the envelope
are processed
by, for example, automated letter-sized postal equipment.
[00011] In accordance with another embodiment of the invention, an assembly
for
mailing an article comprises an envelope, a mailer adapted to be inserted into
the
envelope, and a sleeve positioned inside the pocket of the mailer. The mailer
includes a
first panel, a second panel, a pocket positioned between the first and second
panels, an
access opening to the pocket, and a flap attached to the first panel and
movable relative to
the second panel for closing the access opening to the pocket. The sleeve
includes a first
panel, a second panel joined to the first panel to define a first edge and a
second edge, a
pocket between the first and second panels, an access opening along a portion
of the
second edge for accessing the pocket to insert and remove the article, and a
false bottom
adapted to space the pocket from the first edge by an amount sufficient to
prevent damage
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to the article when the article is positioned inside the sleeve, the sleeve is
positioned
inside the mailer and the sleeve, the mailer, and the envelope are processed
by, for
example, automated letter-sized postal equipment.
[00012] In accordance with another aspect of the invention, a method for
mailing
an article comprises placing the article inside a pocket of a mailing member
having a false
bottom adapted to space said pocket from an edge of the mailing member by an
amount
sufficient to prevent damage to the article during processing. The method
further
comprises inserting the mailing member inside an envelope with an original
address
visible from the exterior of the envelope.
[00013] The features and objectives of the invention will become more readily
apparent from the following Detailed Description taken in conjunction with the
accompanying drawings.
Brief Description of the Figures
[00014] The accompanying drawings, which are incorporated in and constitute a
part of this specification, illustrate embodiments of the invention and,
together with a
general description of the invention given above, and the detailed description
given
below, serve to explain the principles of the invention.
[00015] Fig. 1 is a rear view of an embodiment of a mailer in accordance with
the
invention in an unfolded state;
[00016] Fig. 2 is a front view of the mailer of Fig. 1;
[00017] Fig. 3 is a perspective view illustrating the folding of the mailer of
Fig. 1
fox outbound mailing from a sender to a recipient with the original address
visible, the
return address hidden, and the resizing flap stowed for original mailing;
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[00018] Fig. 3A is a cross-sectional view taken generally along line 3A-3A in
Fig.
3;
[00019] Fig. 4 is a perspective view similar to Fig. 3 illustrating the
folding for
outgoing dispatch from a sender to a recipient;
[00020] Fig. 4A is a cross-sectional view taken generally along line 4A-4A in
Fig.
4;
[00021 ] Fig. 5 is a schematic side view illustrating the mailer of the
invention
being handled by automated processing equipment at a location along the belt
path;
[00022] Fig. 6 is a schematic top view of automated processing equipment
processing the mailer of the invention at a location near a drum changing the
direction of
the belt path;
[00023] Fig. 7 is a perspective view of the mailer of Fig. 1 shown at a stage
of
folding for deploying the resizing flap and arranging the mailer panels so
that the return
address is visible and the original address is hidden;
[00024] Fig. 8 is a view of the mailer of Fig. 1 being handled by postal
equipment
designed for non-letter sized mailpieces after the resizing flap is deployed
for return
mailing;
[00025] Fig. 9 is a rear view of an embodiment of a mailer in accordance with
the
invention in an unfolded state;
[00026] Fig. 10 is a front view of the mailer of Fig. 9;
[00027] Fig. 11 is a perspective view illustrating the folding of the mailer
of Fig. 9
for outbound mailing from a sender to a recipient with the original address
visible and the
resizing flap stowed for original mailing;
[00028] Fig. 12 is a perspective view of a mailer in accordance with an
alternative
embodiment of the invention;
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[00029] Fig. 12A is a perspective view of an alternative embodiment of the
mailer
of Fig. 12;
[00030] Fig. 12B is a perspective view of an alternative embodiment of the
mailer
of Fig. 12;
[00031 ] Fig. 13 is a perspective view showing an embodiment of the mailer of
Fig.
12 without a closing flap being inserted into a separate envelope for mailing;
[00032] Figs. 14A,B are perspective views of a mailer for an article and an
envelope in accordance with an alternative embodiment of the invention;
[00033] Fig. 14C is a perspective view similar to Fig. 14B in accordance with
an
alternative embodiment of the invention;
[00034] Figs. 15A and 15B are front and rear perspective views of a mailer for
an
article and an envelope in accordance with an alternative embodiment of the
invention;
[00035] Figs. 15C is a perspective view of the mailer of Figs. 15A,B
configured for
mailing to a recipient at a return address;
[00036] Figs. 16A and 16B are front and rear perspective views of a mailer and
an
envelope in accordance with an alternative embodiment of the invention;
[00037] Fig. 16C is a perspective view similar to Figs. 16A,B in accordance
with
an alternative embodiment of the invention;
[00038] Fig. 17A is a perspective view of a mailer for an article with a C-
fold flap
configuration and an envelope in accordance with an alternative embodiment of
the
mvenhon;
[00039] Fig. 17B is a perspective view similar to Fig. 17A of a mailer for an
article
with a Z-fold flap configuration and an envelope in accordance with an
alternative
embodiment of the invention;
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CA 02549970 2006-06-13
[00040] Figs. 17C is a perspective view of the mailer of Fig. 16B configured
for
mailing to a recipient at a return address; and
[00041 ] Fig. 18 is a perspective view of a mailer for an article with a C-
fold flap
configuration and an envelope in accordance with an alternative embodiment of
the
invention.
Detailed Description
[00042] With reference to Figs, l and 2, a mailer 10 of the invention
comprises a
generally planar and generally rectangular sheet or blank having opposite side
edges 12
and I4, a top edge 16, a bottom edge 18, a rear side 15 visible in Fig. 1, and
a front side
17 visible in Fig. 2. Mailer 10 includes a first panel 20, a second panel 22
integrally
joined along a transverse fold line 24 extending between side edges 12 and 14
with the
first panel 20, a third panel 26, and a fourth panel 28 integrally joined
along a transverse
fold line 30 extending between side edges 12 and 14 with the third panel 26.
The second
and third panels 22, 26 are joined along a transverse fold line 32 extending
between side
edges 12 and 14. The fold lines 24, 30, and 32 are substantially transverse to
the top and
bottom edges 16, 18 and have a spaced relationship that divides the mailer 10
into panels
20, 22, 26, and 28. The term fold line is used herein to mean a weakened or
scored
portion of the blank for purposes of folding the blank.
[00043] Fold lines 24, 30, and 32 define lines of weakness along which panels
20,
22, 26, and 28 may be folded. The fold lines 24, 30, and 32 are defined such
that panels
20, 22, 26 and 28 have a preferred folding direction. Although not required,
the
directionality may be provided by appropriately scoring fold lines 24, 30, and
32. The
mailer 10 has an open or unfolded position, shown in Fig. 1, wherein the
panels 20, 22,
26, and 28 are adjacent to each other in substantially the same plane and a
closed or
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CA 02549970 2006-06-13
folded position, shown in Fig. 4, wherein the panels 20, 22, 26, and 28 are
folded non-
accordion style into a more compact configuration suitable for mailing. The
invention
contemplates that the top edge 16 may constitute another fold line, as shown
in Fig. 3A,
or may be the nonjoined individual free ends of panels 20 and 38.
[00044] With continued reference to Figs. 1 and 2, the mailer 10 includes a
pouch
or pocket 34 defined near the top edge 16 that is configured to hold and
protect an article
36. The pocket 34 is defined as a space between the first panel 20 and a fifth
panel 38 by
adhesively bonding confronting surface areas of the first and fifth panels 20,
38 with
adhesive 40. Panel 38 is adhesively bonded to the rear side 15 of the mailer
10. The
adhesive 40 defines lateral boundaries for pocket 34 and an edge boundary
connecting the
lateral boundaries proximate and substantially parallel to the top edge 16.
The adhesive
40 may have many different configurations as understood by persons of ordinary
skill in
the art, such as adhesive beads, adhesive dots, adhesive blocks or strips, or
a thin layer of
a coadhesive applied to the panels 20, 38, and is not limited to the
illustrated strips.
[00045] The distance between the top edge 16 and the edge boundary of pocket
34
defines a false bottom, generally indicated by reference numeral 42, for
pocket 34. The
pocket 34 includes an access opening 44 opposite to the false bottom 42 that
is oriented to
face substantially toward the fold line 24 and that is dimensioned between the
lateral
boundaries of pocket 34 to receive the article 36 therethrough for positioning
within
pocket 34. In certain embodiments contingent upon the size of the article 36,
panel 20 is
shorter, as measured between top edge 16 and fold line 24, in a direction
extending
between the top and bottom edges 16 and 18 than panels 22, 26, and 28 as
measured
between adjacent fold lines. The first and fifth panels 20, 38 may be integral
along the
top edge 16 and joined along a fold line, as shown, or the fifth panel 38 may
be a separate
sheet from first panel 20. When the mailer 10 is in a folded condition or
state, the pocket
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CA 02549970 2006-06-13
34 and the article 36 are substantially inaccessible from the exterior of the
mailer 10
without unsealing and unfolding the mailer 10.
[00046] The dimensions of the pocket 34 are predetermined to accommodate the
dimensions of the article 36 and, if the article 36 is a magnetic or optical
memory storage
medium, may be specified to protect the vulnerable storage area of the article
36 from
damage. The pocket 34 has a transverse dimension or width that is slightly
greater than
one dimension of the article 36 and a depth defined by the false bottom 42
that is slightly
less than an orthogonal dimension of the article 36. When the article 36 is
fully received
in pocket 34, the false bottom 42 may permit a portion of the article 36 to be
visible when
the mailer 10 is in an unfolded condition. However, the extent of the false
bottom 42 is
chosen to ensure that an upper edge 58a of transport belts 58 (Figs. 5 and 6)
and other
pressure-exerting components of the postal processing equipment either does
not contact
any portion of the article 36 or does not contact over half of article 36,
depending upon
the requirements of the application. The false bottom 42 can be omitted in
certain
embodiments of the invention, depending upon the dimensions of the article 36,
so that
the article 36 abuts, or nearly abuts, the top edge 16.
[00047] Exemplary articles 36 include stress-sensitive articles formed of a
material,
such as plastic or a polymer, that is susceptible to damage and more
specifically, frangible
or breakable plastic articles such as storage media containing information.
Common
storage media include standard compact disks (CD's) or mini-compact disks
(mini-CD's)
with at least one information-bearing surface. The storage media may carry
audio
information and/or video information. A typical CD, which is formed of
polycarbonate,
has a diameter slightly less than 5 inches (about 12 cm) diameter and a hub
extending
from a diameter of about 1.5 cm (about 0.6") to about 4.6 cm (1.8"). A typical
mini-CD,
for example, has a maximum linear dimension of less than about 3.5 inches. The
article
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CA 02549970 2006-06-13
36 may also have a construction that is not susceptible to damage when handled
by postal
processing equipment but nonetheless should be lifted out of the beltpath when
processed
by postal processing equipment.
[00048] Mailer 10 is constructed to substantially comply with United States
Postal
Service regulations governing automation-compatible mailpieces. To that end,
the mailer
10 height should be between 6.125 inches and 3.5 inches and the mailer 10
length should
be between 5 inches and 11.5 inches, wherein length is the dimension parallel
to an
address 46 when that address 46 is read and the height is the dimension
perpendicular to
the length. The ratio of length to height, or aspect ratio, should be between
1.3 and 2.5
and a thickness between 0.007 inch and 0.25 inch. Postal regulations require
that the
mailer 10 and its contents, article 36, an article 36a or another article,
bend easily when
transported about an 11-inch diameter cylindrical drum 60, as shown in Figs. 5
and 6.
[00049] With reference to Fig. 2, the front side 17 of panel 22 includes an
outbound or original address 46, an optional bar code 48, and postage 50. The
original
address 46 is printed such that address 46 is parallel to the longest folded
dimension or
length of mailer 10. Mailpieces, such as mailer 10, are usually oriented by
postal
processing equipment such that the original address 46 of each mailpiece 10
faces a
consistent direction and has a consistent vertical orientation. Specifically,
the longest
dimension or length of the mailer 10 is aligned parallel to the direction of
motion,
indicated generally by arrow 70 (Fig. 5). The front side 17 of panel 28 may
include a
return address 52 or may be blank so that a recipient can provide a return
address 52 on
panel 28. The destination and return addresses 46, 52 are both located on the
front side
17 of the mailer 10.
[00050] With reference to Figs. 1 and 2, mailer 10 further includes a resizing
extension or flap 54 joined along a transverse fold line 56 with the fourth
panel 28. The
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resizing flap 54 is located at an opposite longitudinal end of the mailer 10
from the pocket
34 that receives the article 36. The resizing flap 54 is stowed away inside
the mailer 10 in
its folded state for dispatch from a source (i.e., sender) at the original
address 46 to an
intended addressee or recipient. An amount of a low-tack adhesive 57 may be
applied to
the resizing flap 54 to adhesively secure flap 54 to fourth panel 28 in the
stowed position
(Figs. 4 and 4A). In an alternative embodiment, flap 54 may be replaced by a
tab-shaped
flap 54a (Fig. 1) that has a dimension measured parallel to fold line 56 less
than a
corresponding dimension of panel 28. The resizing flap 54 may be deployed from
the
stowed position to a deployed position (Fig. 7) by compromising low-tack
adhesive 57, if
present, and unfolding along fold line 56 to extend outwardly from the mailer
10, when
folded so that return address 52 on panel 28 is visible.
[00051] The height of the fourth panel 28, measured between fold lines 30 and
56
may be shorter in height (i.e., the dimension in a direction between the top
and bottom
ends 16 and 18) than the second and third panels 22, 26. However, the summed
height of
the fourth panel 28 and the resizing flap 54 is greater than the height of
either the first
panel 20 or the second panel 22. The resizing flap 54, when deployed, operates
to
increase the effective height of mailer 10 to provide a non-letter or flat
mailpiece. In
certain embodiments, the resizing flap 54, when deployed, increases the height
of the
mailer 10 to exceed 6-I/8 inches, which is a current regulatory threshold for
classifying
mailpieces as letter-sized. However, the invention contemplates that the
threshold height
is related to prospective regulatory guidance and subject to change.
Therefore, in
accordance with the invention, the incremental increase in height (i:e.,
shorter dimension
of mailer 10) provided by the resizing flap 54 is a height increase adequate
to change the
height of the mailer 10 from a height that is letter automation-compatible,
when flap 54 is
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CA 02549970 2006-06-13
stowed, to a height characterizing flat dimensions under postal regulations,
when flap 54
is deployed.
[00052] The resizing flap 54 may be constructed to be maintained in the
deployed
position during processing by the postal service. To that end, the location of
the
transverse fold line 56 should be configured to provide the requisite
stiffness. More
specifically, the location of fold line 56 relative to fold line 30 may be
selected such that
fold tine 56 is not proximate to the transverse fold line 32 of the mailer 10
when folded
with the resizing flap 54 deployed, although the invention is not so limited.
When the
fold lines 30, 56 are arranged in this manner, the underlying panel 22 adds
support and
stiffness to the resizing flap 54. In one specific embodiment, fold line 56 is
located one
inch from the underlying transverse fold line 32, when the resizing flap 54 is
unfolded and
the mailer 10 is folded, in a direction toward a transverse fold line 30. In
another
embodiment, fold line 56 may be approximate aligned with, and overlie, the
transverse
fold line 32 when the resizing flap 54 deployed.
[00053] When the resizing flap 54 is deployed, mailer 10 cannot be handled by
letter-sized processing equipment as described herein. Instead, the mailer 10
with the
deployed resizing flap 54 is handled by flat processing equipment.
[00054] In use and with reference to Figs. 1-8, the mailer 10 is folded in a
non-
accordion style (i.e., surfaces of the panels on opposite sides 15, 17 of
mailer 10 contact
in the folded state, which differs from accordion style folding in which each
pair of
contacting surfaces is on the same side of the folded item) for mailing to
original address
46. With specific reference to Figs. 3, 3A, 4 and 4A, the article 36 is
positioned through
the opening 44 (Fig. 1) into pocket 34. The first and second panels 20 and 22
are folded
at the fold line 24 such that the article 36 and fifth panel 38 are sandwiched
between the
first and second panels 20 and 22. The resizing flap 54 is folded along fold
line 56 over
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the fourth panel 28 and the fourth panel 28 is subsequently folded along fold
line 30 over
the third panel 26 so that flap 54 is captured between the third and fourth
panels 26, 28 in
the folded state. First and second panels 20 and 22 are then folded along fold
line 32 so
that the exposed portions of panels 20 and 22 contact the exposed portions of
panels 26
and 28 to establish a folded or closed state.
[00055] The resizing flap 54 is located in a captured position interposed
between
the third and fourth panels 26 and 28. In the folded state, the article 36 is
sandwiched
between the first and second panels 20 and 22 and the article 36 is
inaccessible from the
exterior of the mailer 10. A sealing member (not shown), such as an adhesive
or a tape, is
used to secure the mailer 10 in the folded state. When the mailer 10 is in a
folded state,
the article 36 is inaccessible from the exterior of the mailer 10, protected
from damage,
and secured from becoming dislodged.
[00056] The sender addresses the mailer 10 with at least the original address
46 and
optional bar code 48 by any conventional technique, such as labeling, typing
or printing.
Other information (not shown), such as a Facing Identification Mark (FIM), an
indication
of the mailer's class, and sender's address, may be provided on the same
surface of mailer
10 as the original address 46, optional bar code 48, and postage 50.
Typically, a group of
mailers 10 is readied for bulk mailing and supplied to the postal service
faced and
oriented. The mailer 10, in its folded state and sealed, is routed as a letter
from the sender
to the recipient at the original address 46 via the postal service.
[00057] Figs. 5 and 6 schematically illustrate the processing of mailer 10 as
an
outbound mailpiece by conventional automated processing equipment comprising
moving
belts, such as transport belts 58, and rotating drums, such as cylindrical
drum 60. The
cylindrical drum 60 is used to change the direction of motion of the transport
belts 58 and,
thereby, to redirect the travel path of mailpieces, such as mailer 10, gripped
between the
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transport belts 58. In such conventional automated processing equipment,
transport belt
58 has a width of about 2 inches and the cylindrical drum 60 has a diameter of
about 11
inches and a width of about 3 inches. Typically, a pair of transport belts 58
grasp a 2-inch
wide height of the opposed parallel faces of each mailpiece, such as mailer
10, and
transport the mailer 10 along a travel path for a purpose such as sorting. The
transport
belts S8 are wound about and driven by the cylindrical drums 60 such that the
mailer 10
must traverse a curved path about the circumference of cylindrical drum 60 in
that portion
of the travel path.
[OOOS8] The mailer 10 is oriented vertically according to the location of
original
address 46 and provided to the transport belts S8 for transport with fold line
32 located
between or proximate to belts S8. Fold lines 24 and 30 are furthest from the
belts S8.
The article 36 or, at the least, the center of the article 36, inside pocket
34 is positioned
above the upper edge S8a of the transport belts S8 so that neither of the
transport belts S8
can contact the portion of mailer 10 directly overlying more than half of the
article 36.
[00059] Mailer 10 is bent about the exterior of cylindrical drum 60 to change
the
direction of the travel path of mailpieces, such as for stacking the mailer
10, along with
other mailpieces, in a bin or receiver 72. In the vicinity of the cylindrical
drum 60, the
mailer 10 is constrained between transport belt 58 and a curved guide rail 74
and
subsequently follows a curved path about the outer circumference of the
cylindrical drum
60.
[00060] Mailer 10 maintains its integrity during transportation and arrives at
the
recipient with the article 36 intact and undamaged as the article 36 or at
least the center of
the article 36 is lifted out of contact with transfer belts 58. Because the
flexing of the
region of the mailer 10 near the pocket 34 is significantly reduced, the risk
of damaging or
breaking the article 36 is significantly reduced when the mailer 10 moves in a
curved path
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CA 02549970 2006-06-13
about the outer circumference of the cylindrical drum 60. At the destination,
the recipient
opens the mailer 10 by compromising the sealing member and unfolding the
panels 20,
22, 26 and 28 to the unfolded or open state (Figs. 1 and 2).
[00061] After unfolding, printed indicia 45 carned by the rear side 15 will be
visible to the recipient and the article 36 will be accessible for removal by
the recipient.
Other types of indicia 45, such as foil stamping, die-cut shapes and
embossing, may be
provided on the rear side 15 or the front side 17 of mailer 10 in addition to
printing.
[00062] With reference to Fig. 7, the recipient may insert the article 36 into
pocket
34, refold the mailer 10 so that the return address 52 is visible from the
exterior of the
mailer 10, secure the mailer 10 in the folded condition, and mail the article
36 to a third
party, such as the original sender. To that end, the first and second panels
20 and 22 are
folded at the fold line 24 such that the article 36 and panel 38 are
sandwiched between the
first and second panels 20 and 22. The resizing flap 54 is deployed by
unfolding along
transverse fold line 56 so that resizing flap 54 extends or projects outwardly
from panel
28. The first and second panels 20 and 22 are folded to overlie the third
panel 26 and then
the fourth panel 28 and the extended resizing flap 54 are folded inwardly to
cover the
original address 46 and thereby, establish the folded or closed state. The
mailer 10 is
sealed by a selectively-activated adhesive (not shown), such as a moisture-
activated
adhesive or tape. In the folded state, the return address 52 is visible.
[00063] As illustrated in Fig. 8, the presence of the deployed resizing flap
54 alters
(i.e., increases) the height of the mailer 10 so that mailer 10 is no longer
within the range
of dimensions characterizing a letter and, therefore, is rejected by the facer
canceller. The
mailer 10, in a closed state and sealed, is routed from the recipient to the
postal location
indicated by the return address 52 via the postal service. Because of the
increased size of
the mailer 10, the mailer 10 is rejected by the facer canceller and instead
handled as a flat
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CA 02549970 2006-06-13
mailpiece. As a result, the mailer 10 is sorted without bending about drums
and rollers
and is handled as a flat transferred for sorting on a conveyor 65. This
increases the
probability that the article 36 will arrive intact at the location of the
return address 52.
[00064] Among the potential applications, the mailer 10 may be used, for
example,
as a two-way or return mailer for article 36, such as would be useful for
return mailing
CD's or DVD's back to the original source. The invention contemplates that the
mailer
IO may incorporate multiple pockets 34 (Fig. 1) for carrying or transporting
multiple
stress-sensitive articles 36. Mailer 10 is typically presorted along with
multiple other
mailers 10 for outbound mailing with the address 46 readable and faced.
Because the
mailers 10 are presented to the postal service in a presorted group, an
automated
processing machine, called the facer canceller, is bypassed during outbound
mail
processing. In orienting mailer 10, the facer canceller processes the mailers
10 both
upside down and right side up. When mailer 10 is processed upside down,
article 36 is
within the beltpath so susceptible to contact by the belts 58. For non-sorted
mailpieces,
the facer canceller faces (i.e., orients) mailpieces through detection of
postage 50 on the
mailer 10 so that the address 52 is readable and may cancel the postage 50
with a
postmark that shows the post office name and cancelling date.
[00065] In transit for return from the recipient to the sender (or another
third party),
the mailer 10 is typically deposited in a public mail collection site. The
mailer 10 and
many other commingled mailpieces also deposited at the collection site are
randomly
oriented as a collection of mixed postal items. The resizing flap 54 increases
the
dimensions of the mailer 10 so that the mailer 10 is too large to ft into the
feeding
mechanism of the facer canceller. As a result, the mailer I O is not
compatible with letter
sorting equipment and is culled from the collection of mixed postal items
manually or by,
for example, the facer canceller itself. The mailer I O is then handled as a
flat mailpiece
-17-
CA 02549970 2006-06-13
per postal regulations during the return mailing so that the mailer 10 is not
exposed to the
belts 58 and drums 60 of automated equipment used to handle letters.
[00066] With reference to Figs. 9 and 10 in which like reference numerals
refer to
like features in Figs. 1-8 and in accordance with an alternative embodiment of
the
invention, a mailer 80 includes a first panel 82, a second panel 84 integrally
joined along
a transverse fold line 86 extending between side edges 88 and 90 with the
first panel 82,
and a third panel 92 integrally joined along a transverse fold line 94
extending between
side edges 88 and 90 with the second panel 84. Although the invention is not
so limited,
mailer 80 includes resizing flap 54, which may be optionally omitted. The fold
lines 86
and 94 are substantially parallel to or transverse to the longest or major
dimension of
mailer 80 and have a spaced relationship to divide the mailer 80 into panels
82, 84 and 92.
Panel 82 may be shorter, as measured between a top edge 96 and fold line 86,
in a
direction extending between the top edge 96 and a bottom edge 98 than panels
84 and 92,
as measured between adjacent fold lines.
[00067] Mailer 80 includes a pouch or pocket 100, similar to pocket 34 (Fig.
1),
defined near the top edge 96 that is configured to hold and protect article
36a, which is
similar or identical to article 36. The pocket 100 is defined as a space
between the first
panel 82 and a fourth panel 102 adhesively bonded to a rear side 104.
Specifically,
confronting surface areas of the first and fourth panels 82 and I02 are joined
by adhesive
105, which defines lateral boundaries for pocket 100 and an edge boundary
connecting the
lateral boundaries proximate and substantially parallel to the top edge 96.
The distance
between the top edge 96 and the edge boundary defines a false bottom,
generally indicated
by reference numeral 106, for pocket 100. The pocket 100 includes an access
opening
107 opposite to the false bottom 106 that is oriented to face substantially
toward the fold
line 86 and that is dimensioned between the lateral boundaries of pocket 100
to receive
-18-
CA 02549970 2006-06-13
the article 36a therethrough for positioning within pocket 100. The adhesive
may have
different configurations, such as adhesive dots, adhesive strips, or a layer
of coadhesive
applied as a pattern to the panels 82 and 102. The first and fourth panels 82
and 102 may
be integral along the top edge 96 and joined along a fold line (not shown), or
the fourth
panel 102 may be a separate piece from the first panel 82. When the mailer 80
is in a
folded condition or state, the pocket 100 and the article 36a are inaccessible
from the
exterior of the mailer 80 without unsealing and unfolding the mailer 80.
[00068] The dimensions of the pocket 100 are predetermined to accommodate the
dimensions of the article 36a. Accordingly, the pocket 100 has a transverse
dimension or
width that is slightly greater than one dimension of the article 36a and a
depth defined by
the false bottom 106 that is slightly less than an orthogonal dimension of the
article 36a.
When the article 36a is fully received in pocket 100, the false bottom 106 may
permit a
portion of the article 36a to be visible when the mailer 80 is in an unfolded
condition.
However, the positioning of the article 36a in pocket 100, including the width
of the false
bottom 106, is chosen to ensure that the transport belts 58 (Figs. 5 and 6)
and other
pressure-exerting components of the postal processing equipment do not contact
the half
of the article 36a above an imaginary line 108 that is substantially parallel
to fold line 86
and that intersects a center 110 of article 36a regardless of rotational
orientation. In other
words, imaginary line 108 is positioned either above or collinear with the
upper edge 58a
of the transport belts 58. As a result, the pocket 100 is positioned such that
only half of
article 36a is located between the transport belts 58 during processing. The
false bottom
106 can be omitted in certain embodiments of the invention, depending upon the
dimensions of the article 36a, so that the article 36a abuts, or nearly abuts,
the top edge
96. The mailer 80 includes original address 46, optional bar code 48 and
postage 50 on a
front side 114 and may also optionally include printed indicia 45 on rear side
104.
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CA 02549970 2006-06-13
[00069] With reference to Fig. 11, the mailer 80 is folded in a non-accordion
style
for mailing to original address 46 by a procedure similar to the procedure
illustrated for
mailer 10 (Fig. 1). The article 36a is positioned through the opening 107 into
pocket 100.
The first and second panels 82 and 84 are folded at the fold line 86 such that
the article
36a and fourth panel 102 are sandwiched between the first and second panels 82
and 84.
The resizing flap 54, if present, is folded along fold line 56 over the third
panel 92 and the
third panel 92 is subsequently folded along fold line 94 over the first panel
82 so that flap
54 is captured between the first and third panels 82 and 92 to establish a
folded or closed
state. In the folded state, the original address 46, bar code 48 and postage
50 are visible.
When oriented by postal processing equipment, the mailer 80 is consistently
oriented
according to the original address 46 such that the fold lines 56 and 86 are
oriented upward
and is positioned above the transport belts 58 (Fig. 5) when captured
therebetween. In the
folded state, the mailer 80 is used as described above in the context of
mailer 10 (Figs. 1-
8).
[00070] With reference to Fig, 12 and in accordance with an alternative
embodiment of the invention, a mailer 120 is provided that includes a pair of
panels 122
and 124 hingeably or foldably joined along a transverse fold line 126 and a
smaller
optional panel or flap 128 hingeably or foldably joined along a transverse
edge or fold line
130 to panel 124. In an alternative embodiment, the flap i28 may be omitted so
that two
discrete panels 122, 124 collectively form mailer 120. Adhesive 132 is applied
across an
inner surface 122a, 124a of panels 122 and 124, respectively, so that the
mailer 120 is
folded to provide a C-fold configuration, or panels 122, 124 are otherwise
joined, with the
confronting inner surfaces 122a, 124a in a contacting relationship. The
adhesive 132
establishes an adhesive bond between the inner surfaces 122a, 124a that
secures the
panels 122 and 124 together to prevent unfolding or separation during postal
processing
-20-
CA 02549970 2006-06-13
and defines the dimensions of a pocket 134 to surround article 36a. Adhesive
132 may be
any coadhesive that provides an adhesive bond with itself and, hence, does not
adhesively
bond with the article 36a when it is pre-positioned between the panels 122 and
124 before
folding or joining. After folding or joining, the panels 122 and 124 are on
opposite sides
of article 36a in a protective spatial relationship, as described above with
regard to mailer
10 (Fig. 1) and mailer 80 (Fig. 8). Persons of ordinary skill in the art will
appreciate that
article 36 (Fig. 1 ) and other types of stress-sensitive articles (not shown)
may be held by
the mailer 120, as welt as mailers 10 and 80.
[00071 ] A front surface of panels 122, 124, visible when the panels 122, 124
are
secured by adhesive 132, bears original address 46, optional bar code 48,
postage 50, etc.
Flap 128 operates as a sealing flap for mailer 120 and may be provided with
adhesive or
tape to provide the seal. Alternatively, flap 128 may be omitted if the
article 36a is fully
concealed between panels 122, 124 or flap 128 may be divided into one or more
laterally-
spaced tabs 128a, 128b that are received in appropriately positioned optional
slits or tab
slots 129 defined in panel 122. In one embodiment, the mailer 120 is letter-
sized with a
height of about 6 inches.
[00072] In an alternative embodiment, the adhesive 132 may be applied to the
inner
surfaces 122a, I24a of panels 122, I24, respectively, in a pattern to define
pocket 134.
This approach may be applicable if transfer of adhesive 132 to the article 36a
is a concern.
After pre-positioning the article 36a between the panels 122 and 124 and
folding, panels
122 and 124 are still on opposite sides of article 36a in a protective spatial
relationship, as
described above with regard to mailer 10 (Fig. 1) and mailer 80 (Fig. 8). In
yet another
alternative embodiment available in conjunction with the definition of pocket
134, article
36a may be inserted into a throat or open end of the pocket 134 defined
between the
lateral boundaries established by the pattern of adhesive 132 after the panels
122, 124 are
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CA 02549970 2006-06-13
folded or joined. Panels 122 and 124 are on opposite sides of article 36a in a
protective
spatial relationship, as described above with regard to mailer 10 (Fig. 1) and
mailer 80
(Fig. 8). As shown in Fig. 12A, pocket 134 may be defined by applying discrete
amounts
of adhesive, such as strips or blocks of adhesive 132a, to one of the panels
122, 124, for
example, panel 124 and folding or otherwise joining panels 122, 124.
[00073] With continued reference to Fig. 12, article 36a is positioned
relative to the
panels 122, 124 such that, when the panels 122, 124 are folded for mailing and
oriented
for processing with transverse fold line 126 downwardly oriented, at least
half of the
article 36a will be located or lifted above the upper edge 58a of the
transport belts 58
(Figs. 5 and 6) to insure safe processing of article 36a, as described above
with regard to
mailers 10 (Fig. 1) and 80 (Fig. 8). In other words, imaginary line 108 (Fig.
10) of article
36a is positioned above the upper edge 58a of transport belts 58. This lift is
provided by
adjusting the article location and/or the position of pocket 134 to define a
false bottom
125 that separates article 36a from fold line 126.
[00074] The invention contemplates that adhesive 132, although described as a
coadhesive, may have any suitable configuration and arrangement for securing
article 36a
between panels 122 and 124. For example, the adhesive 132 may be suitably-
arranged
adhesive dots or stripes, as shown in Fig. 12A. The pocket 134 is configured
to lift at
least half of the article 36a out of the beltpath of high-speed automated
processing
equipment. It is appreciated that one or more parallel lines or beads of
adhesive 132 may
be applied in conjunction with one or more spaced dots of adhesive 132 to
mailer 120 for
purposes of defining the pocket I34.
[00075] Although the pocket 134 is depicted as approximately centered along
the
length of mailer 120 and equidistant from the side edges of the panels 122,
124, the
invention contemplates that the pocket 134 may be located at other transverse
positions by
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CA 02549970 2006-06-13
adjusting the configuration and arrangement of the pattern of adhesive 132.
Panels 122,
124 may have equal lengths and heights or may differ in either relative length
or relative
height. However, the dimensional difference should not relocate the pocket 134
to a
position susceptible to damage from high-speed automated processing equipment
during
transport.
[00076] In use and with continued reference to Fig. 12, after the article 36a
is
positioned relative to the panels 122 and 124 at a location that provides the
requisite
separation from fold line 126, panel 124 is folded along fold line 126 into
registration
with panel 122 or otherwise joined with panel 122 so that adhesive 132
establishes an
adhesive bond when pressure is applied. Alternatively, article 36a may be
inserted into
the optional pocket 134 after the panels 122, 124 are joined by adhesive 132.
If adhesive
132 is applied in a pattern, the regions on the panels 122, 124 that lack
adhesive 132 will
be located in registration with one another and surround the article 36a. Flap
128, if
present, is folded over panel 122 and sealed. The article 36a held inside
mailer 120 is
inaccessible from the exterior of the mailer 120, protected from damage, and
secured from
becoming dislodged against movement inside the mailer 120. In a procedure
similar to
that described for mailer 10 (Fig. 1), mailer 120, in a closed state and
sealed, is routed
outbound from the sender to the destination address 46 via the postal service,
which
typically utilizes automated processing equipment for sorting the mailer 120
according to'
the destination address 46. The recipient opens the mailer 120 by compromising
the
adhesive 132 and/or the optional seal provided by flap 128 to gain access to
the article
36a.
[00077] In certain embodiments, the fold line 130 may be perforated or scored
so
that flap 128 is removable from mailer 120. The recipient may use the mailer
120 as a
protective storage sleeve after receipt. The invention also contemplates that
the flap 128
- 23 -
CA 02549970 2006-06-13
may be used as a resizing flap, as described herein for resizing flap 54
(Figs. 1, 9). The
mailer 120 may be used to return article 36a to the original sender by, for
example,
covering the address 46 with a return address label, reinserting article 36a
into pocket
134, optionally deploying flap 128 as a resizing flap or using flap 128 to
seal the mailer
120, and mailing mailer 120. If the flap 128 is deployed as a resizing flap,
the mailer 120
should be handled as a flat mailpiece by the postal service.
[00078] With reference to Fig. 12A in which like reference numerals refer to
like
features in Fig. 12 and in accordance with an alternative embodiment of the
invention,
pocket 134 of the mailer 120 may be defined by discrete amounts of adhesive
132a
applied in a pattern that defines three boundaries of the pocket 134. Although
illustrated
as adhesive strips or blocks, the invention contemplates that adhesive 132 may
have the
form of adhesive dots or beads. When the panels 122, 124 are folded along fold
line 126
and into contact, an adhesive bond is established by adhesive 132a. Article
36a may then
be inserted into pocket 134 and flap 128, if present, used to seal the mailer
120.
[00079] With reference to Fig. 12B in which like reference numerals refer to
like
features in Fig. 12 and in accordance with an alternative embodiment of the
invention, the
mailer 120 may be provided with two pockets 134a, 134b that are positioned
side-by-side
between panels 122, 124. Each of the pockets 134a, 134b is dimensioned to
receive an
article 36a, although the invention is not so limited. The dimensions (height
and width)
of the mailer 120 is adjusted to accommodate the presence of two pockets 134a,
134b,
each of which is separated from fold line 126 by false bottom 125 dimensioned
to lift the
held articles 36a out of the beltpath of postal processing equipment.
Depending upon the
size and geometry of the article 36a, it is apparent to persons of ordinary
skill that more
than two pockets may be defined between the panels 122, 124. The invention
contemplates that any embodiment of the mailers and sleeves described herein
may be
-24-
CA 02549970 2006-06-13
provided with two or more pockets, similar to pockets 134a, 134b provided for
the
version of mailer 120 shown in Fig. 12B, and that each of these multiple
pockets is
arranged to li$ the held article 36a out of the beltpath of postal processing
equipment.
[00080] With reference to Fig. 13 in which like reference numerals refer to
like
features in Fig. 12 and in accordance with an alternative embodiment of the
invention, the
embodiment of the mailer 120 lacking flap 128 may be treated as an insert that
is inserted
into an envelope 140, which bears an outbound address 143, and mailed outbound
inside
the envelope 140. The article 36a is positioned relative to a f rst edge 144
of mailer 120,
which is defined along fold line 126, so that a second edge 146 of mailer 120,
which is
opposite to first edge 144 and includes an access opening 135 to the pocket
134, can be
inserted into the envelope 140. The invention contemplates that the access
opening 135
may be, for example, along a side edge so long as the false bottom 125 is
remote from the
flap 142 of the envelope 140. A pusher arm 148 transfers the mailer 120 into
envelope
140, which is then sealed and mailed. The envelope 140 has an enclosed space
dimensioned to fully receive the mailer 120. The envelope 140 includes a
sealable flap
142 that is sealed to the body of the envelope 140 after mailer 120 is
inserted.
[00081 ] The distance from edge 144 to the nearest portion of article 36a is
selected
by adjusting the location of the adhesive 132 so that the contacting panels
122, 124 of
mailer 120 may be clamped or gripped during the insertion process, if
necessary for
processing mailer 120, by a gripper arm (not shown) across the false bottom
125 of the
mailer 120 defined between bottom edge 144 and the nearest boundary of pocket
134
without contacting the article 36a. This false bottom 125 between bottom edge
144 and
the nearest portion of article 36a provides an area for gripping the mailer
120 without
damaging the article 36a. Panel 122 or panel 124 may have a shorter height
measured
-25-
CA 02549970 2006-06-13
between the bottom and top edges 144, 146, respectively, so that a portion of
the article
36a is uncovered by the shorter panel and, therefore, exposed and visible.
[00082] The location of the address 143 on the envelope 140, the dimensions of
the
mailer 120 and envelope 140, and the height of the false bottom 125 are chosen
such that
the article 36a will not be damaged by processing with automated processing
equipment,
as described herein. Imaginary line 108 (Fig. 9) is positioned either above or
collinear
with the upper edge 58a of the transport belts 58. As a result, the pocket 100
is positioned
such that less than half of article 36a is located between the transport belts
58 (Figs. 5 and
6) during processing. In various specific embodiments, the mailer 120 and any
of the
other mailers described below, when treated as an insert, may be sized to fit
inside a
standard 6"x 9" envelope, a standard 6" x 9.5" envelope, a 6" x 11.5"
envelope, or any
other sized envelope. The mailer 120 defines a protective sleeve that
maintains the article
36a anchored per postal regulations and that may be inserted into envelope 140
of any
size using existing insertion technology. Additional inserts (not shown), such
as collateral
marketing materials, may be positioned inside envelope 140 and mailed along
with mailer
120. The recipient may retain the mailer 120 after receipt and continue to use
the mailer
120 as a protective storage sleeve for the article 36a.
[00083] With reference to Figs. 14A,B in which like reference numerals refer
to
like features in Fig. 13 and in accordance with an alternative embodiment of
the
invention, the embodiment of the mailer 120 (Fig. 12) bearing flap 128 may
also be
treated as an insert. When so treated, the mailer 120 is inserted into an
envelope 150 for
outbound mailing as a mailing member or assembly 118 for transporting article
36a.
[00084] As shown in Fig. 14A, the article 36a is inserted through the access
opening 135, which is defined near the fold line 130, into the pocket 134 of
mailer 120.
The pocket 134 and article 36a are thus positioned between edges 144, 146.
Various
-26-
CA 02549970 2006-06-13
types of conventional inserters, such as swing arm inserters, friction
inserters, and plow
folders, may be used to position article 36a inside pocket 134. Flap 12$ is
folded over
panel 122 to provide a C-folded arrangement. The invention contemplates that
the access
opening 135 may be, for example, along a side edge so long as the false bottom
125 is
remote from the flap 154 of the envelope 150 and located beneath the original
address
152.
[00085] A gripper arm 121, which is movable generally in at least a direction
123,
includes a clamping arrangement that clamps or grips opposite sides of the
mailer 120 at a
location near edge 144 and along the extent of false bottom 125. Mailer 120
may be
removed from a hopper containing multiple mailers 120, each containing one of
the
articles 36a. The false bottom 125 defines a gripping zone or area across
which the
gripper arm 121 can grip the mailer 120 without damaging the article 36a. The
gripper
arm 121 re-positions the assembly of the mailer 120 and article 36a for
insertion into the
envelope 150 (Fig. 14B).
[00086] As shown in Fig. 14B, the assembly of the article 36a and mailer 120
is
inserted flap-first into envelope 150. During insertion, the pusher arm 148
contacts and
pushes the mailer 120 into envelope 1 SO in a direction generally indicated by
reference
numeral 127. Edge 146, which coincides with fold line 130 between panel 124
and flap
128, of mailer 120 is inserted first into the envelope 150. After insertion,
the false bottom
125 near mailer edge 144 is located adjacent to the envelope flap 154 and
located
generally between a fold line 155 joining envelope flap 154 with a body of
envelope 150
and original address 152.
[00087] The envelope 150 bears an outbound or original address 152 that is
inverted relative to fold line 155 for envelope flap 154. After insertion and
as a
consequence of the orientation of the original address 152 relative to the
fold line 155, the
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CA 02549970 2006-06-13
false bottom 125 of mailer 120 is located between the original address 152 and
the fold
line 155. In other words, the false bottom 125 is located below the original
address 152.
Because the original address 152 is inverted, the envelope 150 is grasped
during
processing by letter-size postal equipment along an envelope edge including
envelope flap
154 such that the false bottom 125 resides in the grasped region. Preferably,
less than half
of article 36a is located between the transport belts 58 (Figs. 5,6) and
contacted by
transport belts 58 during processing. As a result, article 36a has a
significantly reduced
likelihood of being damaged when processed by automated letter-sized
processing
equipment.
[00088] The invention contemplates that, for any of the various embodiments of
the
present invention described herein that utilize an envelope such as the
assembly 118 of
mailer 120 and envelope 150, the envelope may have an access opening for
inserting of
the mailer and optional sleeve that is positioned along any edge of the
envelope. For
example, envelope 150 may have an access opening along a side edge through
which the
article 36a is inserted into pocket 134. Regardless of the specific envelope
construction,
the mailer and optional sleeve are inserted into the envelope such that the
false bottom is
beneath the original address, such as original address 152 on envelope 150,
which lifts the
article 36a from the portion of the envelope contacted by letter-size postal
processing
equipment. The mailer and optional sleeve may be inserted flap-first, flap-
last, edgewise,
etc. without limitation if the mailing address and the false bottom bear the
proper
arrangement and relationship. In addition, the invention contemplates that the
original
address in any of the various embodiments of the present invention described
herein may
be oriented with any orientation relative to the access opening so long as the
orientation of
the original address results in the lift-producing false bottom being located
beneath the
original address. In other words, the arrangement of the false bottom and the
original
-28-
CA 02549970 2006-06-13
address either on the envelope or visible through a window in the envelope
orients the
envelope during processing, rather than the location of the envelope access
opening.
[00089] The envelope 150 is sealed by closing the flap 154 and using sealing
strip
153 to secure the mailer 120 inside and the assembly consisting of mailer 120
and
envelope 150 is deposited with the postal service for delivery to a recipient
at the original
address 152. The assembly of mailer 120 and envelope 150 is forwarded by the
postal
service to a recipient at the original address 152. The recipient compromises
the sealing
strip 153 of envelope 150 to open the envelope 150 and extracts the mailer 120
from the
opened envelope 150 for accessing the article 36a. The used envelope 1 SO may
be
discarded after the mailer 120 is extracted.
[00090] The recipient may retain the mailer 120 after receipt and continue to
use
the mailer 120 as a protective storage sleeve for the article 36a. In this
embodiment of the
present invention, mailer 120 further includes a return address 157, instead
of the original
address 46 (Fig. 12), such that the mailer 120 can be used by recipient to
forward a sealed
assembly consisting of the mailer 120 and article 36a to another addressee,
such as the
original sender or a third party addressee, at the return address 157. To that
end, the
article 36a is inserted into pocket 134 and flap 128 is moved to close the
opening 135 to
the pocket 134 and sealed.
[00091] With reference to Fig. 14C in which like reference numerals refer to
like
features in Fig. 14A,B and in accordance with an alternative embodiment of the
invention, the mailer 120 may further include an amount of a substance 156,
such as
fugitive glue, that is distributed across the flap 128 at locations suitable
to hold the flap
128 in proximate to the panel 122. The flap 128 is C-folded relative to panel
122 to close
the opening 135 to pocket 134 and the assembly of mailer 120 and article 36a
is inserted
flap-last into envelope 1 SO by pusher arm 148. In other words, edge 144 of
mailer 120,
-29-
CA 02549970 2006-06-13
which coincides with fold line 126 for panels 122, 124, is inserted first into
the envelope
150. The outbound address 152 on envelope i50 is oriented such that the false
bottom
125 is between fold line 155 of envelope 150 and the original address 152 and,
consequently, the false bottom 125 is located beneath outbound address 152.
[00092] The envelope 150 is grasped during processing by letter-size postal
equipment along an envelope edge 151 including envelope flap 154 such that the
false
bottom 125 resides in the contacted region. Preferably, less than half of
article 36a is
located between the transport belts 58 (Figs. 5,6) and thus contacted during
processing.
As a result, article 36a has a significantly reduced likelihood of being
damaged when
processed by automated letter-sized processing equipment. The assembly of
mailer 120
and envelope 1 SO is forwarded by the postal service to a recipient at the
original address
152. The recipient compromises the sealing strip 153 of envelope 1 SO and
extracts the
mailer 120 for accessing the article 36a. The envelope 150 may be discarded
after the
mailer 120 and article 36a are extracted therefrom.
[00093] With reference to Figs. 15A-C in which like reference numerals refer
to
like features in Fig. 14A,B and in accordance with an alternative embodiment
of the
invention, mailer 120 may further include a flap 160 that is enlarged with an
extended
length in comparison with flap 128 (Figs. 14A,B). Flap 160, which is
trapezoidal shaped,
is hingeably or foldably joined along the transverse edge or fold line 130 to
panel 124 and
extends to another transverse edge 162. In a folded configuration, the panels
122, 124
extend between the edge 144 located at fold line 126 to the edge 146 located
at fold line
130. The invention contemplates that the flap 160 may be a separate component
joined to
panel 124 along edge 144 as an attached appendage by, for example, adhesive
bonding, as
opposed to the hinged joint configuration provided by fold line 126.
-30-
CA 02549970 2006-06-13
[00094] A line of weakening or latent fold line, such as a score line 164
defined by
a line of discontinuous cuts or slits, and an adhesive region I66 are
positioned between
fold line 130 and edge 162. The score line 164 separates the flap 160 into
section 168
bounded by fold line 130 and section 170 that carnes the adhesive region 166.
The
incremental height, H,, of section 168 is shorter than the incremental height,
HZ, of
section 170 such that, when folded along score line 164 to form the
arrangement shown in
Fig. 15C, at least a portion of the adhesive region 166 contacts panel 122.
Section 170 is
larger in surface area than section 168. The adhesive region 166 may be of a
peel and seal
type strip having a removable protective barrier covering pressure-sensitive
adhesive or
may be a formulation that is moisture or pressure activated.
[00095] As shown in Figs. 15A,B, article 36a is inserted into opening 135 of
pocket 134 and flap 160 is folded over panel 122 in direction 172 (i.e., C-
folded). The
assembly of the mailer 120 and the article 36a is inserted flap-first into an
envelope 150 in
a direction generally indicated with reference numeral 173 such that the false
bottom 125
is located adjacent to the envelope flap 154. Because the original address 152
is inverted,
the envelope 1 SO is grasped by letter-size postal equipment along an envelope
edge
including envelope flap 154 such that the false bottom 125 resides in the
grasped region.
The assembly of mailer 120 and envelope 1 SO is forwarded by the postal
service to a
recipient at the original address 152. The recipient compromises the sealing
strip 153 of
envelope 150, extracts the mailer 120 for accessing the article 36a, and
optionally discards
the used envelope 150.
[00096] As shown in Fig. 15C, the mailer 120 may be configured to forward the
article 36a to a recipient at the return address 157 without the use of
envelope 150. To
that end, the article 36a is inserted into the pocket 134 and flap 160 is
folded along the
score line 164 such at least a portion of the adhesive region 166 contacts
panel 122 for
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adhesively bonding the flap 160 to the panel 122. This seals the article 36a
inside the
pocket 134 and effectively lengthens the height of the mailer 120 by the
incremental
height, H,, of section 168. Because of the increased height, the mailer 120 is
not handled
by automated letter-sized processing equipment when in route to a recipient at
the return
address 157 and bypasses this equipment, which could potentially damage the
article 36a
during handling. Flap 160 operates in a manner similar to resizing flap 54
(Figs. 1, 9) for
increasing the height of mailer 120.
[00097] In certain embodiments, the incremental height, H,, of section 168 of
the
deployed flap 160 increases the height of the mailer 120 to exceed 6-1/8
inches, which is
a current regulatory threshold for classifying mailpieces as letter-sized.
However, the
invention contemplates that the threshold height is related to prospective
regulatory
guidance and subject to future change. Therefore, in accordance with the
present
invention, the incremental increase in height provided by the flap 160 is a
height increase
adequate to change the height of the mailer 120 from a initial height (with
the flap 160
stowed) that fits within the envelope 150 to a final height (when flap 160 is
deployed)
characterizing flat dimensions under postal regulations.
[00098] In alternative embodiments of the invention, the flap 160, as well as
resizing flap 54, may be located along a side edge of mailer 120 so that the
length of the
mailer 120 can be extended to prevent handling by letter-sized postal
processing
equipment. For example, the deployed flap 160 may extend the length of mailer
120 to
exceed 11-1/2 inches, which is a current regulatory threshold for classifying
mailpieces as
letter-sized. Changing the length modifies the aspect ratio of the mailer 120
with the
same result as changing the height. However, the invention contemplates that
the
threshold length is related to prospective regulatory guidance and subject to
future
change.
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[00099] The invention also contemplates that an end user may maintain a stock
of
any of the mailers described herein, such as mailer 120, and use the mailers,
at the
discretion of the end user, with the resizing flap, such as flaps 160, either
undeployed so
that mailer is letter automation-compatible, or with the resizing flap
deployed so that the
mailer bypasses automated letter-sized processing equipment and has a height
or length
characterizing flat dimensions under postal regulations. This would provide a
flexible
stockpile of article mailers that can be selectively configured for handling
either as a
letter-sized mailpiece or as a flat mailpiece. When the resizing flap is not
deployed, the
mailer may be sent as a letter-size group of items that are handled
collectively as a bulk
mailing and, thus, are not exposed to the facer canceller.
[000100] With reference to Figs. 16A,B in which like reference numerals refer
to
like features in Figs. 15A-C and in accordance with an alternative embodiment
of the
invention, an assembly 220 including an envelope 174 with a transparent or
translucent
window 176 or an aperture (not shown) in the envelope 174 that is unfilled by
a window,
a mailer 180 similar to mailer 120 (Fig. 15A), and a sleeve 200 that is
inserted into mailer
180. Sleeve 200, which is similar to the embodiment of mailer 120 shown in
Fig. 13, is
configured to receive article 36a and the assembly of article 36a and sleeve
200 are
inserted into mailer 180 to form another mailing member or assembly 300 for
transporting
article 36a. Envelope 174 includes a flap 175 bearing a sealing strip 178 used
to seal the
envelope 174 by folding flap 175 along fold line 171 with the sealing strip
178 activated
and forming an adhesive bond between sealing strip 178 and a portion of
envelope 174.
[000101] Mailer 180 differs from mailer 120 (Fig. 15A) in that the false
bottom 125
(Fig. 15A) is absent. Instead, the sleeve 200 incorporates a false bottom 202
that
positions article 36a relative to the envelope 174 and mailer 180 such that
the article 36a
will not be damaged or, at the least, is unlikely to be damaged by processing
with
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automated processing equipment, as described herein. False bottom 202 is
created by
adhesively bonding, or otherwise joining by, for example, stapling, the panels
204, 206 of
the sleeve 200 together in a manner similar to the adhesive bond that creates
false bottom
125, as described herein. The panels 204, 206 are joined along a fold line
210, which
defines an edge 209 of the bonded panels 204, 206. Defined between panels 204,
206 of
sleeve 200 is a pocket 208 positioned between edge 209 and an opposite edge
205. An
access opening 207 into pocket 208 is defined along or near edge 205 of the
bonded
panels 204, 206. The invention contemplates that the access opening 207 to
pocket 208
may be defined along a side edge of the bonded panels 204, 206, wherein the
sleeve 200
has two side edges joining edges 205, 209, so long as the pocket 208 is
separated from
edge 209 by false bottom 202. One boundary of the pocket 208 is supplied by
the false
bottom 202 and the lateral boundaries of the pocket 208 are defined by bonding
or
otherwise joining confronting strip sections 212x, 214a and 212b, 214b of the
panels 204,
206 with, for example, adhesive (not shown).
[000102] The assembly 220 is formed by inserting the article 36a through
access
opening 207 and at least partially into a pocket 208. One boundary of the
pocket 208 is
suppiied by the false bottom 202 and the lateral boundaries of the pocket 208
are defined
by bonding or otherwise joining confronting strip sections 212a, 214a and
212b, 214b of
the panels 204, 206 with, for example, adhesive (not shown). The pocket 208
confines
the article 36a and lifts the article 36a away from edge 210.
[000103] Mailer 180 includes panels 181, 182 that are bonded or otherwise
joined
along confronting strip sections 183x, 184a and 183b, 184b with, for example,
adhesive
185 and joined along a fold line 186 to bound a pocket 188. The fold line 186
constitutes
one edge 191 of the bonded panels 181, 182. A flap 190, which is identical or
substantially similar in construction and function to flap 160 (Figs. 15A-C),
is attached to
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panel 181 along a fold line 192, which constitutes a second edge 193 of the
bonded panels
181, 182. Consequently, flap 190 may be beneficial for using the mailer 180 to
forward
the article 36a to a return address 194 (Fig. 16B). The mailer 180 includes an
access
opening 185 to the pocket 188 defined near or along edge 193 through which the
article
36a is inserted into pocket 188 and removed from pocket 188. The invention
contemplates that the access opening 185 to pocket 188 may be defined along a
different
edge of the bonded panels 181, 182, so long as the sleeve 200 is inserted into
pocket 188
with a suitable orientation of false bottom 202.
[000104] Mailer 180 also includes a removable label 196 that bears an outbound
or
original address 198. Initially and as best shown in Fig. 16B, the return
address 194 is
covered or otherwise obscured by the label 196 during the outbound mailing so
that only
the original address 198 is visible. In one embodiment, the label 196 is a
thin trapezoidal
sheet of, for example, paper stock that is adhesively bonded in a removable
manner to
panel 181 of the mailer 180. For example, the label 196 may be removably
bonded to
panel 181 along a edge strip by a low strength pressure sensitive adhesive.
During
transfer to the recipient at the original address 198, the envelope protects
the removable
label 196.
[000105] In use, the article 36a is inserted into the pocket 208 of sleeve
200, which
is preferably dimensioned to at least partially and, preferably, fully receive
the article 36a
so that the article 36a is at least partially hidden. This assembly is then
inserted into the
pocket 188 of mailer 180 in a direction indicated by the single-headed arrow
222 to form
another assembly. Pocket 188 is preferably dimensioned to at least partially
and,
preferably, fully receive that sleeve 200 so that the sleeve 200 is at least
partially hidden.
The orientation of the original address 198 determines the orientation in
which the sleeve
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CA 02549970 2006-06-13
200 is inserted into mailer 186. The flap 190 is C-folded in the direction
indicated by
single-headed arrow 226 so that flap 190 contacts panel 182.
[000106] This assembly is then inserted flap-first into the envelope 174 with
the fold
line 192 defining the leading end in a direction indicated by the single-
headed arrow 224
to create assembly 220. The envelope 174 and mailer 180 are arranged, and the
window
176 positioned in envelope 174, such that the original address 198 is visible
through the
window 176 to an observer outside the envelope. This arrangement also places
the false
bottom 202 of the sleeve 200 adjacent to an edge 177 of the envelope 174. The
false
bottom 202 ensures that the article 36a will not be damaged by processing with
automated
processing equipment, as described herein, when the envelope 174 is contacted
across
regions near the edge 177 by automated postal equipment. The orientation of
the original
address 198 determines which edge of the envelope 174 is a bottom edge. After
the flap
175 of envelope 174 is sealed using sealing strip 178, the envelope 174 is
dispatched
through the postal service to a recipient at the original address 198.
[000107] The recipient at the original address 198 compromises the sealing
strip 178
to remove the assembly of the article 36a, the sleeve 200, and the mailer 180
and proceeds
to remove the article 36a from the sleeve 200. The envelope 174 may be
discarded. The
original recipient may forward the mailer 180, along with sleeve 200 and
article 36a,
through the postal service to another recipient at the return address 194. To
do so, the
original recipient removes the label 196 to reveal the return address 194 and,
after
inserting article 36a into sleeve 200 and inserting this assembly into mailer
180, deposits
the assembly with the postal service for delivery to the recipient at the
return address 194.
The flap 190 may be deployed so that the postal service does not handle the
mailer 180
with automated letter-sized equipment, which protects article 36a against
damage during
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CA 02549970 2006-06-13
handling and transport. Consequently, the orientation of the sleeve 200 within
the mailer
180 does not determine article safety during this phase of handling by the
postal service.
[000108] With reference to Fig. 16C in which like reference numerals refer to
like
features in Figs. 15A,B and in accordance with an alternative embodiment of
the
invention, the label 196 on mailer 180 may comprise a piggyback label having a
first
panel 230 that is strongly bonded to the mailer 180 and a removable second
panel 232 that
is removably bonded with panel 230. Panel 230 carries the return address 194
and panel
232 carnes the original address 198. The label 196 is positioned on the mailer
180 such
that the original address 198 is visible through window 176. This embodiment
of the
mailer 180 is assembled to form assembly 220 and delivered in envelope 174 to
the
original address 198 by the postal service as described above. The recipient
at the original
address 198 can forward the mailer 180 to a third party at the return address
194 by
removing panel 232 to reveal the return address 194 and depositing the sealed
mailer 180
with the postal service. Flap 190 is deployed to ensure that the mailer 180 is
not damaged
during handling by automated letter-sized equipment at the postal service.
[000109] The invention contemplates, as appreciated by persons of ordinary
skill in
the art, that the removable label 196 and envelope 170 may be used in
conjunction with
the embodiments of the present invention shown in Figs. 13, 14A-C and 15A-C.
[000110] With reference to Fig. 17A in which like reference numerals refer to
like
features in Figs. 16A,B and in accordance with an alternative embodiment of
the
invention, a mailer 240 differs from mailer 180 (Fig. 15A) in that the label
196 (Figs.
16A,B) is absent and in that flap 190 (Figs. 16A,B) include a section 242 that
replaces
section 170 (Figs. 16A,B). The envelope 174, sleeve 200, and mailer 240
constitute a
mailing member or assembly 310 for transporting article 36a. Mailer 240
Section 242 is
extended in height in comparison with section 170. An original address 244 is
printed
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CA 02549970 2006-06-13
directly on section 242 and the return address 194 is printed directly on
panel 181 of the
mailer 180. Flap 190 is C-folded to place the original address 244 at a
readable location
visible through window 176. The mailer 240 is inserted into envelope 174 such
that the
original address 244 is visible through window 176 when mailed to the original
address
244. Mailer 240, containing the assembly of article 36a and sleeve 200,
operates in a
similar manner to mailer 180 and sleeve 200 to protect the article 36a against
damage
during handling by the postal service.
[000111 ] The recipient may optionally obscure the original address 244 with,
for
example, a marker and deposit the sealed mailer 180 for dispatch to another
recipient at
the return address 194. As explained above, flap 190 is configured such that
the postal
service does not handle the assembly of mailer 240 and sleeve 200 with letter-
sized
automated postal equipment, so as to protect article 36a against damage during
handling
and transport to a recipient located at the return address 194.
[000112] With reference to Figs. 17B,C in which like reference numerals refer
to
like features in Fig. 17A and in accordance with an alternative embodiment of
the
invention, the original address 244 may be printed on a surface of section 242
that is
visible through window 176 when the flap 190 is Z-folded and the mailer 240 is
placed
inside envelope 174 for outbound mailing to a recipient at the original
address 244, as
shown in Fig. 17B. The mailer 240 is thus configured for forwarding to a
recipient at the
return address 194, as shown in Fig. 17C, by reverse folding the flap 190 to
assume a C-
folded arrangement with panel 182. In this C-folded arrangement, the surface
of section
242 bearing the original address 244 faces panel 182 so that the original
address 244 is
hidden.
[000113] Flap 190 may then be deployed, at the discretion of the recipient, to
forward the article 36a to another recipient located at the return address
194, as explained
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CA 02549970 2006-06-13
above. The deployed flap 190 prevents the postal service from handling mailer
240 with
automated letter-sized equipment, which protects article 36a against damage
during
handling and transport.
[000114] With reference to Fig. 18 in which like reference numerals refer to
like
features in Figs. 17A and in accordance with an alternative embodiment of the
invention,
a mailer 260 differs from mailer 240 (Fig. 17A) in that section 262 is added
to section
242 (Fig. 17A). Section 262 is joined along a perforated score line 268 with
section 242
and is removable from section 242. An original address 270 is printed directly
on section
262, as opposed to being printed onto section 242. The mailer 260 is inserted
into
envelope 174, with the section 262 folded against panel 182. The original
address 270 is
positioned on a surface of section 262 so that original address 270 is visible
through
window 176 in the C-folded arrangement. Mailer 260 and sleeve 200 operates in
a
similar manner to mailer 240 and sleeve 200 to protect the article 36a against
damage
during handling by the postal service. The assembly of sleeve 200, mailer 260,
and
envelope 174 is deposited in the mail for delivery to a recipient at the
original address
270.
[00011 S] The recipient may optionally dispatch the article 36a to another
recipient at
the return address 194 (not shown) by removing the removable section 262 by
manipulation of the score line 268 sufficient to scission section 262 along
score line 268.
As explained above, flap 190 is configured such that the postal service does
not handle
mailer 260 with automated letter-sized equipment, so as to protect article 36a
against
damage during handling and transport. In an alternative embodiment of the
present
invention, flap 190 may be Z-folded, so that section 242 contacts panel 181
when placed
inside envelope 174, to situate the original address 270 at a location
readable through the
window 174. The folding is similar to the folding of mailer 240 shown in Fig.
17B.
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CA 02549970 2006-06-13
[000116] The mailers and sleeves described herein may be formed from any
suitable
material, such as plastic, paper stock or cardboard, and may be fabricated
from a larger
sheet of material by any suitable process, such as die cutting. The material
may have a
stiffness sufficient to withstand processing in automated mail processing
equipment
without sustaining significant damage, yet lightweight for purposes of
manufacturability
and to minimize mailing costs.
[000117] In accordance with the present invention, the false bottom, whether
in one
of the mailers or incorporated into one of the sleeves, provides lift that
significantly
reduces the risk that the pocket-held article will be contacted during postal
processing to
an extent sufficient to damage the article. Generally, regardless of how the
mailer, either
with or without a sleeve is inserted into an envelope, the false bottom is
beneath the
original address. In other words, the false bottom is contacted by regions of
the transport
belts, spindles, and drums of the processing equipment such that the held
article is
unlikely to be damaged by the resulting contact.
[000118] While the present invention has been illustrated by the description
of
embodiments example thereof, and while the embodiments have been described in
considerable detail, they are not intended to restrict or in any way limit the
scope of the
appended claims to such detail. Additional advantages and modifications will
readily
appear to those skilled in the art. The invention in its broader aspects is
therefore not
limited to the specific details, representative apparatus and method and
illustrative
examples shown and described. Accordingly, departures may be made from such
details
without departing from the scope or spirit of applicant's general inventive
concept.
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