Note: Descriptions are shown in the official language in which they were submitted.
CA 02590815 2007-06-04
TITLE OF THE INVENTION
IRREGULARLY SHAPED ENVELOPE AND METHOD FOR MAKING IRREGULARLY
SHAPED ENVELOPES
FIELD OF THE INVENTION
The present invention relates to irregularly shaped envelopes and a
method for manufacturing such envelopes.
BACKGROUND OF THE INVENTION
Envelopes and processes for manufacturing envelopes from envelope
blanks are well known. Envelopes are typically formed by a high-speed,
automated process comprising using an envelope blank, having front and rear
panels, folding the side flaps inwardly on the blank form, applying an
adhesive
material to the exposed surfaces of the side flaps and folding the blank to
secure the side flaps to the front panel and create the closure of the sides
along the folded side flaps, resulting in a standard envelope. In the mass
production of such envelopes, it is important to minimize the number of
folding and adhesive application steps and adjustments needed to
manufacture each envelope. It is also important to create an envelope that is
suitable for mass manufacturing, insertion, operating within and passing
through mailing and mail sorting equipment. Further, the shape and surface
of an envelope provides a space for the sender to advertise or display designs
and information to attract potential customers.
A number of prior art references disclose changes in the shape of an
envelope blank or changes in the manufacturing of envelopes that optimize
the envelope for mass-handling operations, mail sorting and inserting
equipment. For example, U.S. Patent No. 7,172,107 of Kranz, issued
February 6, 2007, describes an envelope in which the overlap profile of the
side flaps is optimized for automated mail handling processes. U.S. Patent
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Publication No. U.S. 2004-0226986 Al of Purcell discloses an optimized
application of an adhesive layer to create an envelope that is better suited
for
automatic insertion equipment.
Conventionally, envelopes are rectangular in shape and provide little
opportunity for creative designs to be applied to the envelope. A sender who
wishes to use the surface of the envelope for advertising must fit their
design
within the space and shape of a conventional rectangular envelope. A number
of prior references exist which are designed to create interest in the shape
and
design of an envelope. For example, U.S. Patent No. 6,619,539 of Schluger,
issued September 16, 2003, teaches a rectangular shaped envelope with miter
joint corners to pique the interest of the recipient and motivate the
recipient
to open the envelope. The mailer design disclosed in Canadian Patent
Application No. 2,412,549 provides a shaped structure, but is constructed
from a number of sheets and interlocking components to create a non-linear
design and thus, is not suited for large volume envelope manufacturing and
mailing applications.
It is an object of the present invention is to provide a method for
manufacturing an irregularly shaped envelope that can support non-linear
designs, is suitable for mass-mailing applications and which requires minimal
changes to existing envelope manufacturing methods and machinery.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention there is
provided an irregularly shaped envelope. The irregularly shaped envelope
comprises a rear panel having a top edge, a bottom edge and two side edges
and a front panel having a top edge, a bottom edge and two side edges, the
front panel and rear panel secured to each other along their bottom edges. A
closure flap is secured to the top edge of the front panel and a side flap is
secured to one of the side edges of one of the rear or front panels, the side
flap being folded over a corresponding side portion of that panel, creating
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interior and exterior side flap surfaces. A corresponding side edge of the
other panel is fixedly joined to the exterior side flap surface, and side
portions
of the rear and front panels adjacent said other side edges are fixedly
joined,
a shape being formed in said fixedly joined side portions so as to provide a
non-linear edge to the envelope.
In accordance with another aspect of the present invention there is
provided a method of forming an irregularly shaped envelope. The method of
forming an irregularly shaped envelope comprises the steps of providing a
rear panel having a top edge, a bottom edge and two side edges; a front
panel having a top edge, a bottom edge and two side edges, the front panel
and rear panel secured to each other along their bottom edges; a closure flap
secured to the top edge of the front panel; and a side flap secured to one of
the side edges of one of the rear or front panels. Folding the side flap to
cover a portion of that panel, creating interior and exterior side flap
surfaces.
Applying an adhesive to at least a portion of the exterior side flap surface,
closure flap and side portions of the rear panel and front panel adjacent said
side edges, opposite the side flap. Folding the rear panel over the front
panel.
Securing the exterior folded side flap surface to one of the front or rear
panels
and securing side portions of the rear and front panels adjacent said side
edges opposite the folded side flap. And forming a shape in said secured side
portions of the rear and front panels.
As will be discussed in more detail subsequently, the envelope
according to the present invention provides improved design opportunities.
The method of manufacturing the irregularly shaped envelope requires
minimal disruption to existing envelope manufacturing processes.
While the invention will be described in conjunction with illustrated
embodiments, it will be understood that it is not intended to limit the
invention to such embodiments. On the contrary, it is intended to cover all
alternatives, modifications and equivalents as may be included within the
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spirit and scope of the invention as defined by the present patent
specification
as a whole.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention will become apparent upon
reading the following detailed description and upon referring to the drawings
in which:
FIGURE 1 is a plan view of an unfolded, planar envelope blank;
FIGURE 2 is a perspective view of a partially folded envelope blank after
adhesive regions are formed;
FIGURE 3 is a perspective view of a partially formed envelope from the
blank of Figure 2;
FIGURE 4 is a plan view of an irregularly shaped envelope;
The present invention will now be described by way of a non-limiting
description of certain detailed embodiments.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
In the following description, similar features in the drawings have been
given identical reference numerals where appropriate. All dimensions
described or suggested herein are intended solely to illustrate an embodiment.
These dimensions are not intended to limit the scope of the invention that
may depart from these dimensions.
Turning to Figure 1, there is shown an envelope blank 2 in accordance
with an embodiment of the present invention. The envelope blank comprises a
rear panel 4, a front panel 6, a closure flap 8 and a side flap 10. The side
flap
10 is shown adjacent the front panel 6. Alternatively, a side flap 11 may be
located adjacent the rear panel 4, as shown in dotted lines in Figure 1. A
side
portion 12 of the front panel 6 and a side portion 14 of the rear panel 4 are
shown to illustrate the process of forming the irregularly shaped envelope. It
is to be understood that a conventional envelope blank with a second side flap
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13, shown in dotted lines in Figure 1, also may be used to form the
irregularly
shaped envelope.
Figure 2 shows a partially folded envelope blank. The side flap 10 is
5 folded inwardly over a corresponding portion of the rear panel to create a
folded side flap 16. An adhesive layer is applied to adhesive regions 18, 20,
22 and 24. The adhesive may be any conventional adhesive material and
different adhesive materials may be applied in different regions of the
envelope.
Figure 3 illustrates the envelope with the rear panel 4 and side portion
14 folded over to confront corresponding portions of the front panel, side
portion of the front panel and folded side flap 16. As the rear panel 4 is
folded
over the front panel, it is secured to the folded side flap 16. The side
portion
14 is secured to the side portion 12 via the mating of adhesive regions 20 and
18, creating a shape-forming area 26.
As shown in Figure 3, an irregular or non-linearly shaped edge 28 can
be formed in the shape-forming area 26 by a conventional cutting step. For
example, a partial outline of the shape of a face, figure, product or the
like,
appearing on the envelope, can be created along the irregular edge 28. As
shown in Figure 4, a snowman 34 printed on the rear panel and shape-
forming area 26 illustrates this feature of the invention. Of course, the
front
panel also may carry a design which conforms to the irregularly shaped edge
28.
Figure 4 shows the full design surface and shape of the finished
irregularly shaped envelope. A design may be printed on the envelope blank 2
before the envelope is formed, or the design may be printed on the finished
irregularly shaped envelope. A traditional stamp area 30 and optional address
window 32 are also illustrated in Figure 4. The stamp area 30 and address
space 32 are shown on the conventional back side of the envelope but may be
placed on the conventional front side of the envelope.
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The envelope design of the present invention provides an irregularly
shaped envelope that can be used for mass-mailing applications. It is to be
understood that the dimensions of the present invention can accommodate
but are not limited to the dimensions and requirements of mail systems such
as those of Canada Post.
Although the present invention has been described by way of a detailed
description in which various embodiments and aspects of the invention have
been described, it will be seen by one skilled in the art that the full scope
of
this invention is not limited to the examples presented herein. The invention
has a scope which is commensurate with the claims of this patent specification
including any elements or aspects which would be seen to be equivalent to
those set out in the accompanying claims.
