Envelope having improved overlap profile

Abstract

An envelope assembly is provided for improved performance of a mailing envelope in the automated mail handling process. The envelope comprises a front panel having top, bottom and side edges and forming an envelope front surface, side flaps extending front the side edges, a rear panel extending from the bottom edge and combining with the side flaps to form an envelope rear surface, and a closure flap extending from the top edge for securing the envelope in a closed position. The configuration and attachment of the side flaps and the rear panel are especially beneficial as described herein.

1 . An envelope having a top edge, a bottom edge and first and second side edges, the envelope comprising: 
 a front panel;    a rear panel interconnected with the front panel along the bottom edge of the envelope, the rear panel having a top edge and first and second side edges, at least a portion of the rear panel between the first and second side edges having a width that is reduced from the panel width of the rear panel along the bottom edge;    first and second side flaps interconnected with the front panel along a line of weakness to define opposite first and second side edges for the envelope as the first and second side flaps are folded toward the rear panel, the first and second side flaps extending inwardly a sufficient span as folded from the line of weakness to extend beyond the first and second side edges of the rear panel, the first and second side flaps being secured to the rear panel to cooperatively form an envelope rear surface positioned opposite of the front panel;    a closure flap interconnected with the front panel along a common top edge;    wherein the rear panel overlaps the side flaps, and adhesive is placed on respective rearwardly facing surfaces of the side flaps to adhere the side flaps to the rear panel; and    wherein a first transition point is formed at an intersection of the first side flap and the rear panel top edge and a second transition point is formed at an intersection of the second side flap and the rear panel top edge, each of the first and second transition points having a transition angle defined between a tangent line to the rear panel top edge at the respective transition point and a tangent line to the respective side flap at the respective transition point, the transition angles being about 15 degrees or less.    
   
   
       2 . The envelope of  claim 1 , wherein: 
 each side flap has a bottom edge, an inside edge, and a top edge;    the adhesive is placed on the respective rearwardly facing surfaces of the side flaps so that the adhesive is spaced between approximately 3 mm and 5 mm from the respective inside edges; and    the adhesive is placed on the respective rearwardly facing surfaces of the side flaps so that the adhesive is spaced between approximately 3 mm and 5 mm from the respective top edges.    
   
   
       3 . The envelope of  claim 2 , wherein respective side flap top edges and respective side flap inside edges meet at a configuration selected from the group consisting of a small-radius curve and an angle.  
   
   
       4 . The envelope of  claim 1 , wherein: 
 each side flap has a bottom edge, an inside edge, and a top edge; and    the adhesive is placed on the respective rearwardly facing surfaces of the side flaps to approximately 3 mm from the respective inside edges and to approximately 3 mm from the respective top edges.    
   
   
       5 . The envelope of  claim 4 , wherein respective side flap top edges and respective side flap inside edges meet at a configuration selected from the group consisting of a small-radius curve and an angle.  
   
   
       6 . The envelope of  claim 5 , wherein the transition angle of each of the first and second transition points is about 10 degrees or less.  
   
   
       7 . The envelope of  claim 6 , wherein the rear panel top edge forms a throat region sloping downward from the first and second transition points.  
   
   
       8 . An envelope comprising: 
 a front panel having a generally rectangular shape and forming an envelope front surface, the front panel defining opposite first and second side edges of the envelope;    a rear panel interconnected with the front panel along a common bottom edge, the rear panel having a top edge and first and second side edges, the first and second side edges having a rapidly tapering region defining an area of panel width proximal to the bottom edge that is reduced from the panel width along the bottom edge, a portion of the rear panel first and second side edges above the rapidly tapering region extending substantially parallel to the respective first and second side edges of the envelope;    first and second side flaps interconnected with the front panel along common opposite side edges, the side flaps being fixedly joined to the rear panel to form an envelope rear surface positioned opposite of the envelope front surface, the side flaps being sandwiched between the rear panel and the front panel; and    a closure flap interconnected with the front panel along a common top edge and having an outer edge forming a set of shoulder areas proximal to the top edge; and    wherein a first transition point is formed at an intersection of the first side flap and the rear panel top edge and a second transition point is formed at an intersection of the second side flap and the rear panel top edge, each of the first and second transition points having a transition angle defined between a tangent line to the rear panel top edge at the respective transition point and a tangent line to the respective side flap at the respective transition point, the transition angles being about 15 degrees or less.    
   
   
       9 . The envelope of  claim 8 , wherein: 
 adhesive is placed on respective rearwardly facing surfaces of the side flaps to adhere the side flaps to the rear panel; and    each side flap has a bottom edge, an inside edge, and a top edge.    
   
   
       10 . The envelope of  claim 9 , wherein respective side flap top edges and respective side flap inside edges meet at a configuration selected from the group consisting of a small-radius curve and an angle.  
   
   
       11 . The envelope of  claim 10 , wherein the adhesive is placed on the respective rearwardly facing surfaces of the side flaps so that an area extending approximately 3 mm from the respective inside edges and approximately 3 mm from the respective top edges are free of the adhesive.  
   
   
       12 . The envelope of  claim 11 , wherein: 
 the adhesive is approximately 3 mm from the respective inside edges of the rearwardly facing surfaces of the side flaps; and    the adhesive is approximately 3 mm from the respective top edges of the rearwardly facing surfaces of the side flaps.    
   
   
       13 . The envelope of  claim 11 , wherein: 
 the adhesive is between 3 mm and 5 mm from the respective inside edges of the rearwardly facing surfaces of the side flaps; and    the adhesive is between 3 mm and 5 mm from the respective top edges of the rearwardly facing surfaces of the side flaps.    
   
   
       14 . The envelope of  claim 13 , wherein the transition angle of each of the first and second transition points is about 10 degrees or less.  
   
   
       15 . The envelope of  claim 14 , wherein the rear panel top edge forms a throat region sloping downward from the first and second transition points.  
   
   
       16 . The envelope of  claim 9 , wherein the adhesive is placed on the respective rearwardly facing surfaces of the side flaps so that an area extending approximately 3 mm from the respective inside edges and approximately 3 mm from the respective top edges are free of the adhesive.  
   
   
       17 . The envelope of  claim 16 , wherein: 
 the adhesive is approximately 3 mm from the respective inside edges of the rearwardly facing surfaces of the side flaps; and    the adhesive is approximately 3 mm from the respective top edges of the rearwardly facing surfaces of the side flaps.    
   
   
       18 . The envelope of  claim 16 , wherein: 
 the adhesive is between 3 mm and 5 mm from the respective inside edges of the rearwardly facing surfaces of the side flaps; and    the adhesive is between 3 mm and 5 mm from the respective top edges of the rearwardly facing surfaces of the side flaps.