Note: Descriptions are shown in the official language in which they were submitted.
BLANK FOR MAKING A MAILER AND MAILER MADE THEREBY
This application relates to a blank for making a mailer and to a mailer made
thereby.
As is known, various types of mailers have been used for the mailing and
shipment of documents and things. For example, US Patents 6,820,799 and
6,564,994 each describe an expandable envelope construction made from a
single blank.
It is an object of this invention to provide a one piece blank that can be
readily folded into a mailer having an improved construction over previously
known mailers.
It is another object of the invention to provide a mailer of improved
construction over previously known mailers.
It is another object of the invention to provide a mailer of improved
construction that can be manufactured on readily available equipment as
efficiently as possible
It is another object of the invention to provide a mailer that can be used on
commonly available high speed envelope insertion equipment
It is another object of the invention to provide an expandable mailer with
improved strength and durability of mailer in the closure area
1
CA 2822697 2017-09-05
CA 02822697 2013-08-01
It is another object of the invention to provide an expandable mailer with
improved openness of the interiors of the corners to minimize jamming or
restriction.
It is another object of the invention to provide an expandable mailer that
can be hand assembled using peel and stick tape on side tabs.
It is another object of the invention to provide an expandable mailer that
has improved construction without score lines on the front panel.
It is another object of the invention to provide an expandable mailer that
has greater capacity than similar sized mailers
It is another object of the invention to provide an expandable mailer that
can be modified to be a reusable portfolio with reusable closure.
Briefly, the invention provides a one piece blank made of cardboard or any
other suitable material for a mailer.
In one embodiment, the blank includes a front panel, a pair of side flaps
that extend from the front panel, a back panel and a closure panel wherein the
side flaps are to be folded over the front panel, the back panel then secured
to
and over the side flaps and the closure panel closed over the front panel to
form a
mailer.
The front panel and side flaps are formed with tabs with rounded edges
that are to overlie each other when folded into a mailer. The rounded edges on
the tabs minimize the chance that the corners will catch on other objects and
tear
when the tabs are glued on the outside of the back panel. When glued on the
inside of the back panel, the rounded tabs reduce the potential for inserted
contents to get caught on the corner of the tabs and jam.
2
CA 02822697 2013-08-01
In another embodiment, the blank includes a front panel, a pair of side flaps
that extend from the front panel, a back panel and a closure panel wherein the
side flaps are to be folded over the front panel, the back panel then secured
to
and over the side flaps and the closure panel closed over the back panel to
form a
mailer.
In this embodiment, each side flap of the blank is formed with a foldable tab
to reinforce the upper corners of the mailer and the back panel is formed with
a
rhombic shaped tab on each side to reinforce the lower corners of the mailer.
In still another embodiment, the blank includes a front panel, a pair of side
flaps that extend from the front panel, a bottom panel and a closure panel
wherein
the side flaps are to be folded over the front panel and each other to form a
center
seam of a mailer made from the blank, the bottom panel then secured to and
over
the side flaps and the closure panel closed over the side flaps to form a
mailer.
These and other objects and advantages of the invention will become more
apparent from the following detailed description taken in conjunction with the
accompanying drawings wherein:
Fig. 1 illustrates a view of a blank used to make a mailer in accordance with
the invention;
Fig. 2 illustrates the blank of Fig. 1 with the side flaps folded over the
front
panel;
Fig. 3 illustrates the blank of Fig. 1 with the front panel and flaps folded
over the back panel;
Fig. 4 illustrates the blank of Fig. 1 with the closure panel closed over the
front panel to form a mailer;
3
CA 02822697 2013-08-01
Fig. 5 illustrates a view of a blank of another embodiment used to make a
mailer in accordance with the invention;
Fig. 6 illustrates a view of a mailer made from the blank of Fig. 5;
Fig. 7 illustrates a view of a blank of another embodiment used to make a
.. center seam mailer in accordance with the invention; and
Fig. 8 illustrates a view of a mailer made from the blank of Fig. 7.
Referring to Fig. 1, the blank 10 is a one-piece construction made of
cardboard or any other suitable material for a mailer. The blank 10 includes a
front
panel 11, a pair of side flaps 12 that extend from the front panel 11, a back
panel
13 and a closure panel 14.
The front panel 11 has a rectangular section 15, a pair of triangular
sections 16 and a pair of tabs 17. Each triangular section 16 extends from a
respective corner of the rectangular section 15 and each tab 17 extends from a
respective one of the pair of triangular sections 16 and the rectangular
section 15.
In addition, a pair of fold lines 18 are provided wherein each fold line 18 is
disposed between a triangular section 16 and a tab 17 and the tab 17 has a
rounded outer edge.
The rectangular section15 of the front panel 11 may have score lines, i.e. a
horizontal score line spaced from the back panel 13, a pair of vertical score
lines
extending from the horizontal score line and along the side edges and angular
score lines extending from the intersections of the horizontal and vertical
score
lines to the corners of the rectangular section 15.
Each side flap 12 extends laterally from the rectangular section 15 of the
front panel 11 and has a vertical score line 19 dividing the side flap 12 into
a first
section 20 extending from the front panel 11 and a second section 21. Each
first
4
CA 02822697 2013-08-01
*
section 20 has a triangular section 22 at one end extending from a triangular
section 16 of the front panel 11 and a tab 23 extending from an opposite end.
Each second (outer) section 21 is of generally rectangular shape with a
horizontal
edge 24 at each end.
In addition, each side flap 12 has an integral tab 25 at the lower end, as
viewed, that extends from the triangular section 22 of the first section 20
and the
edge 24 of the second section 21 and that has a rounded outer edge 26. The tab
25 is separated by score lines 27 from the two sections 20, 21. with the
vertical
score line 19 extending therethrough.
In addition, a vertical fold line 28 is provided between each side flap 12 and
the front panel 11.
The back panel 13 extends from the front panel 11 for folding over the front
panel 11 to define a pocket. The back panel 13 has a first horizontally
disposed
score line 29 dividing the back panel 13 into a first trapezoidal section 30
extending from the front panel 11 and a rectangular section 31 and a second
horizontally disposed score
line 32 separating the rectangular section 31 of
the back panel 13 from a second trapezoidal section 33.
Alternatively, the back panel 13, as the front panel 11, may be made
without the score lines 29, 32 where the blank 10 is made of light weight
materials. Thus, the score lines are used for heavier weight materials to
enhance
the foldability function of the blank and, in the case of light weight
materials, the
score lines enhance the aesthetics of the mailer formed from the blank.
The closure panel 14 extends from the back panel 13 being separated by a
fold line 34 and has a horizontally disposed score line 35 dividing the
closure
5
CA 02822697 2013-08-01
panel 14 into a trapezoidal section 36 extending from the back panel 13 and a
second section 37.
Referring to Fig. 4, when folded, the blank 10 forms a mailer 38.
The closure panel 14 has an adhesive 39 on the second section 37 for
adhering to the front panel 11 to close the pocket in the mailer 38 formed
from the
blank 10 after filling with material. This adhesive 39 may be of any suitable
type,
such as, permanent, cohesive, pressure sensitive and the like, and form, such
as,
a block, dots, lines, and the like. As illustrated, a suitable releasable
cover sheet
or strip 40 is applied over the adhesive 39 for transport purposes.
In addition, the closure panel 14 includes a horizontally disposed integral
tear-off strip 41 between the adhesive 39 and the trapezoidal section 36 of
the
closure panel 14. Upon removal of the tear-off strip 41 from the remainder of
the
closure panel 14, access may be had to the pocket of the mailer 38.
Referring to Fig. 2, in order to form the mailer 38 of Fig. 4, the side flaps
12
extending from the front panel 11 are provided with a suitable adhesive 42 in
order to be secured to the back panel 13. To this end, the adhesive 42 is
applied
to the underside, as viewed, of the second section 21 (i.e. the outer section)
of
each side flap 12 and provided with a releasable cover sheet or tape (not
shown).
As such, the product of Fig. 2 may be sold as shown with peel and seal tape on
the side flaps 12 and closure panel 14.
Alternatively, the product of Fig. 2 could be manufactured with the side
flaps 12 glued shut which is more common for mailers.
When folding the blank 10 into the mailer 38, each side flap 12 is folded
over the front panel 11 with the adhesive 42 facing upwardly as shown in Fig.
2. If
not previously removed, the cover strips covering the adhesive 42 are then
6
CA 02822697 2013-08-01
removed from the folded over side flaps 12. At this time, the triangular
section 22
of each side flap 12 overlies a triangular section 16 of the front panel 11
and the
rounded tab 25 of each side flap 12 overlies a tab 17 of the front panel 11.
Next, as shown in Fig. 3, the back panel 13 is folded about the fold line 34
.. to overlie the front panel 11 and the folded over side flaps 12 (or vice
versa) and
the exposed adhesive 42 on the side flaps 12 secures the back panel 13 to the
side flaps 12 thus forming a pocket between the front panel 11 and back panel
13.
At this time, the top edge of the front panel 11 is spaced inwardly of the top
edge of the back panel 13. In particular, the second trapezoidal section 33 of
the
.. back panel 13 is exposed beyond the top edge of the front panel 11. In
addition,
the ends of the first trapezoidal section 30 of the back panel 13 overlie the
tabs 23
of the side flaps 12 and the rectangular section 31 of the back panel 13
overlies
the outer sections 21 of the side flaps 12 extending between and to the
vertical
score lines 19 of the side flaps 12.
The closure panel 14 may then be folded over the front panel 11 without
being secured in place for shipment in bulk quantities.
When placed in use, the closure panel 14 is lifted away from the front panel
11 and the pocket of the mailer 38, as indicated in Fig. 3, so that materials
may be
placed in the pocket. Upon filling the pocket to capacity, the mailer expands.
In
this respect, the first section 20 of each side flap 12 pivots about and away
from
the front panel 11; the second section 21 of each side flap 12 pivots relative
to the
first section 20 of the side flap 12 while remaining flat and parallel to the
front
panel 11; the first trapezoidal section 30 of the back panel 13 pivots about
and
away from the front panel 11 and the rectangular section 31 of the back panel
13
remains flat and parallel to the front panel 11.
7
CA 02822697 2013-08-01
In addition, the tabs 23 of the side flaps 12 flex relative to the inner
sections
21 of the side flaps 12 to maintain the lower corners of the filled mailer 38
in a
closed condition.
Thereafter, the releasable cover sheet or strip 40 is removed from over the
adhesive 39 and the closure panel 14 folded over the front panel 11, as
indicated
in Fig. 4, allowing the adhesive 39 to secure the closure panel 14 to the
front
panel 11 in a secure manner. At this time, the trapezoidal section 36 of the
closure
panel 14 overlies the second trapezoidal section 33 of the back panel 11 as
well
as the rounded tabs 17 of the front panel 11. In addition, depending upon the
filling of the mailer 38, the second or outer section 37 of the closure flap
14 flexes
more or less about the score line 35 to accommodate the thickness of the
materials in the pocket of the mailer 38.
Opening of the closed mailer 38 may be accomplished by removing the
tear-off strip 41 in a conventional manner.
Referring to Fig. 5, in another embodiment, the blank 42 has a front panel
43 of rectangular shape; a pair of side flaps 44 extending from the front
panel 43,
a back panel 45 extending from a bottom edge, as viewed, of the front panel 43
and a closure panel 46 extending from a top edge, as viewed, the front panel
43
on an opposite side from the back panel 45.
The front panel 43 is separated from the back panel 45 by a fold line 47
and from the closure panel 46 by a fold line 48. In addition, the front panel
43 may
be formed with score lines, i.e. a pair of horizontal score lines 49 spaced
from the
back panel 45 and closure panel 46, a pair of vertical score lines 50
extending
from the horizontal score lines 49 and angular score lines 51 extending from
the
8
CA 02822697 2013-08-01
intersections of the horizontal and vertical score lines 49, 50 to the corners
of the
front panel 43.
Each side flap 44 is separated from the back panel 45 by a fold line 52 and
has a vertical score line 53 dividing the side flap 44 into a first section 54
extending from the front panel 43 and a second section 55. The first section
54 of
each side flap 44 has an angular score line 56 at one end extending from the
front
panel 43 and the second section 55 has a horizontal score line 57 extending
from
the angular score line 56 to an edge of the flap 44. The angular score line 56
and
horizontal score line 57 of each side flap delimits a tab 58.
The first section 54 of each side flap 44 has an angled lower edge that is to
overlie an angular score line 51 of the front panel 43 when the side flap 44
is
folded over the front panel 43. The second section 55 of each side flap 44 has
a
horizontal edge colinear with a horizontal score line 49 of the front panel 43
when
the side flap 44 is folded over the front panel 43.
An adhesive 59 is applied to the second section 55 (i.e. the outer section)
of each side flap 44 and is provided with a releasable cover sheet or strip
(not
shown). As indicated, the adhesive may be applied as one or more blocks or in
any other suitable manner.
The back panel 45 extends from the front panel 43 for folding over the front
panel 43 to define a pocket. The back panel 45 has a horizontally disposed
score
line 60 dividing the back panel 45 into a trapezoidal section 61 extending
from the
front panel 43 and a rectangular section 62. In addition, a pair of tabs 63
extends
from the back panel 45. Each tab 63 extends from a respective end of the
trapezoidal section 61 and the rectangular section 62 of the back panel 45 and
is
9
CA 02822697 2013-08-01
of rhombic shape. When the back panel 45 is folded over the front panel 43,
each
tab 63 lies over and within the contour of the first section 54 of a side flap
44.
The closure panel 46 extends from the fold line 48 and has a horizontally
disposed score line 64 dividing the closure panel 46 into a trapezoidal
section 65
extending from the front panel 43 and a second section 66.
As above, the closure panel 46 includes a horizontally disposed integral
tear-off strip 67 in the second section 66. Upon removal of the tear-off strip
67
from the remainder of the closure panel 46, access may be had to the pocket of
the mailer 38.
In this embodiment, the tear-off strip 67 has a pair of projections 68 at each
end and the outer section 55 of each side flap 44 is provided with a semi-
circular
recess 69 to receive a projection.
As shown in Fig. 5, the upper end of each side panel 44 is spaced
downwardly, as viewed, from the top edge of the front panel 43 as represented
by
the fold line 48 in order to accommodate for the thickness of the substrate
used.
Thick substrates require this downwardly space so that, when folded over,
material does not pinch or bunch at the intersection of the tab 58 of a side
flap 44
and the trapezoidal section 65 of the closure panel 46 along fold line 48.
Also, the trapezoidal section 61 of the back panel 45 is of slightly smaller
width than the front panel 43 to provide an inward spacing to accommodate for
the
thickness of the substrate used. Thick substrates require this inward space so
that, when folded over, material does not pinch or bunch at the intersection
of the
inner section 54 of a side flap 44 and the trapezoidal section 61 of the back
panel
45 along fold line 47.
CA 02822697 2013-08-01
Also, the rectangular section 62 of the back panel 45 is of the same width
as the distance between the vertical score lines 50 in the front panel 43.
Referring to Fig.6, the blank 42 is foldable on itself to form a mailer 70. In
this respect, the back panel 45 is first folded about the fold line 47 onto
the front
panel 43. At this time, the top edge of the back panel 45 is spaced inwardly
of the
top edge of the front panel 43. In particular, a trapezoidal section of the
front panel
43 is exposed beyond the top edge of the back panel 45.
Next, with any releasable cover strips removed, the two side flaps 44 are
folded over the back panel 45 so that the adhesive 59 secures the outer
sections
55 of each side flap 44 to the rectangular section 62 of the back panel 45. At
this
time, the rounded tabs 58 of the side flaps 44 project above the top edge of
the
back panel 45. At this time, each tab 63 lies under the inner section 54 and
within
the contour of the inner section 54 as seen in Fig. 6.
The closure panel 46 may then be folded over the back panel 45 without
.. being secured in place for shipment in bulk quantities.
When placed in use, the closure panel 46 is lifted away from the back panel
45 and the pocket of the mailer 70, as indicated in Fig. 6, so that materials
may be
placed in the pocket. Upon filling the pocket to capacity, the mailer expands.
In
this respect, the first (inner) section 54 of each side flap 44 pivots about
and away
from the front panel 43; the second (outer) section 55 of each side flap 44
pivots
relative to the first section 54 of the side flap 44 while remaining flat and
parallel to
the front panel 43; the trapezoidal section 61 of the back panel 45 pivots
about
and away from the front panel 43 and the rectangular section 62 of the back
panel
45 remains flat and parallel to the front panel 43.
11
CA 02822697 2013-08-01
In addition, the tabs 63 of the back panel 45 flex relative to the trapezoidal
section 61 of the back panel 45 to maintain the lower corners of the filled
mailer
70 in a closed condition.
Thereafter, with a suitable adhesive on the closure panel 46, the closure
panel 46 is folded over the back panel 45 allowing the adhesive to secure the
closure panel 46 to the back panel 45 in a secure manner. At this time, the
trapezoidal section 65 of the closure panel 46 overlies a trapezoidal section
of the
front panel 43 as well as the rounded tabs 58 of the side flaps 44. In
addition,
depending upon the filling of the mailer 70, the second or outer section 66 of
the
closure panel 46 flexes more or less about the score lines 48, 64 to
accommodate
the thickness of the materials in the pocket of the mailer 70.
Opening of the closed mailer 70 may be accomplished by removing the
tear-off strip 67 in a conventional manner.
Referring to Fig. 7, wherein like reference characters indicate like parts as
above, a blank 71 for forming a center seam mailer 72 as indicated in Fig. 8
includes a front panel 73 of rectangular shape; a pair of side flaps 74
extending
from opposite sides of the front panel 73 for folding over the front panel 73,
a
bottom panel 75 extending from a bottom edge of the front panel 73 for folding
over the front panel 73 and a closure panel 76 extending from the front panel
73.
The front panel 73, as in the above embodiments, may include a pair of
horizontal score lines 49 spaced from the bottom panel 75 and closure panel
76, a
pair of vertical score lines 50 extending from the horizontal score lines 49
and
angular score lines 51 extending from the intersections of the horizontal and
vertical score lines 49, 50 to the corners of the front panel. As viewed, the
score
12
CA 02822697 2013-08-01
lines 49, 50, 51 define a peripheral frame of four trapezoidal sections about
the
front panel 73
Each side flap 74 has a vertical score line 77 parallel to an edge of the
front
panel 73, a pair of horizontal score lines 78 and a pair of angular score
lines 79.
Each horizontal score line 78 extends from an end of the vertical score line
77
and each
angular score line 79 extends from an intersection of the vertical score line
77 and
a respective horizontal score line 78 to divide the side flap 74 into a
trapezoidal
section 80 extending from the front panel 73, a rectangular section 81
extending
from the trapezoidal section 80 and a tab 82 extending from the trapezoidal
section 80 and the rectangular section 81. As illustrated, each tab 82 has a
rounded outer edge.
As illustrated, each side flap 74 has a width greater than one-half the width
of the front panel 73 for folding over the front panel 73 in overlapping
manner. In
addition, at least one the side flaps 75 has an adhesive 83 thereon for
securing
the side flaps 74 together in overlying relation.
The bottom panel 75 has a horizontally disposed score line 84 spaced from
a bottom edge of the front panel 73 to divide the bottom panel 75 into a
trapezoidal section 85 extending from the front panel 73 and a rectangular
section
86. In addition, the bottom panel 75 has an adhesive 87 on the rectangular
section 86 for adhering to the side flaps. In the illustrated embodiment, the
side
flaps 74 are to be folded over the front panel 73 with the bottom panel 75
folded
over the side flaps 74. In this case, the adhesive 87 is on the top side of
the
bottom panel 75, as viewed. However, where the bottom panel 75 is first folded
over the front panel 73 followed by folding of the side flaps 74 over the
front panel
13
CA 02822697 2013-08-01
,
73 and bottom panel 75, the adhesive 87 would be on the underside of the
bottom
panel 75.
The bottom panel 75 is of a width equal to the horizontal distance between
the vertical score lines 50 on the front panel 73.
The closure panel 76 has a horizontally disposed score line 88 dividing the
closure panel 76 into a trapezoidal section 89 extending from the front panel
73
and a second section 90. In addition, an adhesive 91 is disposed on the second
section 90 for adhering to the side flaps 74 when the side flaps are folded
over
each other. For example, a remoistenable adhesive may be used for high speed
heavy insertion applications and manual insertion and a peel and seal adhesive
tape arrangement may be used for manual insertion.
The closure panel 76, as the bottom panel 75, is of a width equal to the
horizontal distance between the vertical score lines 50 on the front panel 73
and is
provided with a tear strip 67 with projections, as above.
A fold line 92 is also disposed between the front panel 73 and the closure
panel 76.
In order to form the center seam mailer 72, the side flaps 74 of the blank 71
are first folded over the front panel 73 and adhesively secured together via
the
adhesive 83 to form a center seam. Next, the bottom panel 75 is folded over
the
front panel 73 and side flaps 74 and secured to the side flaps 74 via the
adhesive
87 to form a pocket. At this time, the tabs 82 at the bottom edges of the side
flaps
74 underlie the ends of the trapezoidal section 85 of the bottom panel 75 to
securely close the bottom two corners of the pocket. In addition, the closure
panel
76 remains in an unfolded state so that access may be had to the pocket for
filling
with materials, such as, sheets of paper.
14
CA 02822697 2013-08-01
Upon filling the pocket of the mailer 72, the mailer 72 expands to
accommodate the materials inserted therein. In this regard, the front panel 73
and
side flaps 74 remain parallel and flat while moving away from each other as
the
trapezoidal sections 80 of the side flaps 74 and the corresponding trapezoidal
sections of the front panel 73 angulate relative to each other.
After filling of the pocket of the mailer 72, the closure panel 76 is folded
over the side flaps 74 and secured thereto via the adhesive 90. At this time,
the
tabs 82 at the top edges of the side flaps 74 underlie the ends of the
trapezoidal
section 89 of the closure panel 76 to securely close the top two corners of
the
mailer 72.
Opening of the mailer can be carried out by removing the tear strip 67.
Of note, the blank 71 may be oriented on automated folding and filling
equipment so that the pocket is formed with the closure panel 76 oriented as
indicated in Fig. 7 for top end filling or with the closure panel oriented 90
from the
position indicated in Fig. 7 for side filling. Similarly, the blanks 10, 42 of
the other
embodiments may be oriented in the same manner.
The center seam construction of Fig.7 may be modified to use a different
type of closure panel for mailing purposes or for filing purposes. For
example, use
may be made of a tuck/tab closure. In this embodiment, each side flap 74 would
be provided with an angularly disposed slot (not shown) and the closure panel
76
would have a second section 90 shaped to provide a pair of outstanding ear-
like
tabs (not shown) for sliding into the slots of the folded over side flaps 74
when the
closure panel 76 is folded to close the pocket of the construction. This
embodiment is particularly useful for paperboard and heavier substrates
including
CA 02822697 2013-08-01
corrugate as well as plastic and is particularly useful for mailing with the
addition
of an adhesive 91 and a tear strip 67, as above.
Of note, closure of the above described embodiments of the invention may
be accomplished using a button and string design or clasp enclosure rather
than
the tear strip type of closure described.
The invention thus provides an improved mailer construction as well as
blank that can be folded into a mailer in an economical manner.
Further, the invention provides a blank that can be made of any suitable
material for making a mailer, such as, paper, paperboard, chipboard and
corrugated board and plastic.
16
