Mailer and method of forming mailers

Abstract

A mailer is formed from a blank in the form of a single sheet of material having opposite sides each printed with variable imaging. The blank includes opposite and spaced apart edges. A first fold line extends transversely between the edges of the blank defining adjacent first and second panels. A second fold line extends transversely between the edges of the blank defining a third panel adjacent the second panel. Each panel has ends corresponding to the edges of the blank. Inwardly foldable flaps are formed along the ends of the second panel. The third panel is folded about the second fold line and adhesively secured to the inwardly folded flaps so as to define a first pocket having an open end. Frangible portions are formed along the ends of each first and third panel and adhesively secured to each other to define a second pocket having an open end.

1 . A two-way mailer comprising: 
 a blank having: 
 opposite and spaced apart edges;  
 a first fold line extending transversely between the edges of the blank defining adjacent first and second panels, a second fold line extending transversely between the edges of the blank defining a third panel adjacent the second panel, each panel having ends corresponding to the edges of the blank;  
 inwardly foldable flaps formed along the ends of the second panel, the third panel being folded about the second fold line and adhesively secured to the inwardly folded flaps so as to define a first pocket having an open end; and  
 frangible portions formed along the ends of each first and third panel and adhesively secured to each other to define a second pocket having an open end.  
   
   
   
       2 . A two-way mailer as set forth in  claim 1 , wherein the blank includes a third fold line formed in the second panel to define a flap that can be folded over the open end of the first pocket.  
   
   
       3 . A two-way mailer as set forth in  claim 2  including an adhesive securing the flap to one of the second and third panels for sealing the open end of the first pocket.  
   
   
       4 . A two-way mailer as set forth in  claim 1 , wherein each end of the second panel includes a pair of transverse cuts that facilitate folding of the inwardly folding flaps over the second panel, one of the transverse cuts being aligned with the second fold line, and the other of the transverse cuts being spaced apart from the third fold line.  
   
   
       5 . A two-way mailer as set forth in  claim 1 , wherein the blank includes a line of perforations formed along the ends of each first and third panel to facilitate a separation of the frangible portions therefrom.  
   
   
       6 . A two-way mailer as set forth in  claim 5 , wherein the first pocket is substantially enclosed in the second pocket and is revealed upon separation of the frangible portions from the first and third panels.  
   
   
       7 . A two-way mailer as set forth in  claim 1 , wherein a fourth fold line is formed in the first panel to define a second flap that can be folded over the open end of the second pocket.  
   
   
       8 . A two-way mailer as set forth in  claim 7  including an adhesive securing the second flap to one of the second and third panels for sealing the open end of the second pocket.  
   
   
       9 . A two-way mailer as set forth in  claim 1  including a plurality of perforations formed along the first fold line to facilitate a separation of the first and second panels.  
   
   
       10 . A two-way mailer as set forth in  claim 1 , wherein the blank includes opposite sides each having variable imaging preprinted thereon.  
   
   
       11 . A two-way mailer as set forth in  claim 1 , wherein one of the panels includes a window that allows viewing of contents contained in the first pocket.  
   
   
       12 . A device for manufacturing two-way mailers from a web having opposite printable sides, the device comprising: 
 a reel stand for supporting the web and from which the web of paper is unwound;    a print station having at least two spray heads, the spray heads being spaced apart;    a plurality of rollers supporting one portion of the web in a generally horizontal manner so that one of the printable sides is presented to one of the spray heads for printing thereon, the plurality of rollers supporting another portion of the web in a generally horizontal manner so that the other of the printable sides is presented to the other of the spray heads.    
   
   
       13 . A device as set forth in  claim 12 , wherein the spray heads are vertically spaced apart.  
   
   
       14 . A device as set forth in  claim 13 , wherein at least one of the plurality of rollers guides the web generally orthogonally along a generally vertical path after one of the printable sides has been printed by one of the spray heads.  
   
   
       15 . A device as set forth in  claim 14 , wherein at least another of the plurality of rollers guides the web generally orthogonally from the vertical path toward the other of the spray heads so that the other of the printable sides can be printed.  
   
   
       16 . A device as set forth in  claim 12  including a scoring mechanism that scores tranversely extending fold lines along the web defining a plurality of separable blanks therealong, wherein each blank has at least three panels foldable about the fold lines to define at least one pocket, and wherein each panel extends transversely between opposite ends.  
   
   
       17 . A device as set forth in  claim 16 , wherein the scoring mechanism scores longitudinal fold lines along each end of each panel.  
   
   
       18 . A device as set forth in  claim 17  including a cutting mechanism for forming spaced apart transversely extending cuts at the ends of at least one panel of each blank, the cuts defining inwardly foldable flaps at the ends of the at least one panel of each blank.  
   
   
       19 . A device as set forth in  claim 18  including a folding mechanism for folding the flaps inwardly toward each other, the folding mechanism including a bracket having a bottom edge that engages the foldable flaps as the blank is fed to the folding mechanism, the bottom edge sloping downwardly toward a trailing flat portion that presses and folds the foldable flaps in a position overlying the blank.  
   
   
       20 . A device as set forth in  claim 19 , wherein the bracket includes a leading edge extending upwardly and obtusely from the bottom edge engaging the foldable flap and displacing the flap inwardly toward the position overlying the blank.  
   
   
       21 . A device as set forth in  claim 20 , wherein the bracket includes a top surface twisted in a helical manner between the leading edge and the trailing flat portion.  
   
   
       22 . A device as set forth in  claim 20  including a mechanism for displacing the foldable flaps inwardly as the web is fed to the folding mechanism to ensure proper engagement between the foldable flaps and the leading edge of the bracket.  
   
   
       23 . A method of forming an envelope having an insert disposed therein, the method comprising the steps of: 
 providing a blank having a plurality of panels;    placing the insert onto the blank prior to folding of the plurality of panels; and    folding the panels in an overlying manner so as to define a pocket with the inserts supported therein.    
   
   
       24 . A method as set forth in  claim 23  including the step of applying an adhesive to form a bond between the insert and the blank securing the insert to the blank during formation of the pocket.  
   
   
       25 . A method as set forth in  claim 23  including the step of applying a fugitive adhesive to form a releasable bond between the insert and the blank securing the insert to the blank during formation of the pocket, whereafter the fugitive adhesive dries and releases the bond between the insert and the blank so that the insert is freely removable from the pocket by a recipient of the envelope.