BACKGROUND OF THE INVENTION
[0001] This invention relates generally to a self-sealed envelope assembly having a free
insert therein, and more particularly to such an assembly wherein the insert is immobilized
in place by means of self- adhering material at least partially securing the envelope
plies together and in contact with the insert.
[0002] Various types of stuffed sealed envelopes having free inserts therein are known from
the prior art. For example, U.S. Patent No. 4,010,889, commonly owned herewith, discloses
a free insert immobilized in place within the outer envelope plies by means of retention
chips bearing against opposed side and end edges of the insert. U.S. Patent No. 3,777,971
discloses a free insert being held in place within a stuffed sealed envelope by means
of embossments struck from one of the outer envelope plies and presenting shoulders
abutting against edges of the insert. Still further, in U.S. Patent No. 3,339,827,
a free insert is immobilized within a stuffed sealed envelope by means of adhesive
used in securing the outer envelope plies together.
[0003] All three of these constructions, however, are to some degree difficult to assemble
because of the production accuracy required in assuring that the insert may be extracted
without interference. This is a particular problem in the assembly of continuous envelopes
in accordance with the aforementioned '827 patent since even a small portion of the
glue used in securing the outer envelope plies together will render the insert difficult
to extract if the glue touches any portion of the insert. Hence, extreme care must
be taken during manufacture of the envelope assemblies in assuring that the glue streams
are spaced a slight distance away from the peripheral edge of the insert so that such
edges are unattached to the glue, as required.
[0004] Other prior art relating to the invention may be found in U.S. Patent Nos. 3,208,662
and 3,208,663 wherein slef-stick adhesive is utilized for retaining fold-flap envelopes
onto a support web without the adhesive sticking to the envelopes themselves. Neither
patent, however, discloses a stuffed sealed envelope assembly as in the invention.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide a stuffed sealed envelope assembly
having a free insert maintained in registry therein without shifting relative to the
outer envelope plies, the construction of such envelope assembly avoiding the difficulties
during production and insert extraction experienced with prior art stuffed sealed
envelope assemblies having free inserts.
[0006] Another object of this invention is to provide such a stuffed sealed envelope assembly
capable of being manufactured quickly and economically as the inserts are placed in
contact with the means securing the outer envelope plies together yet remain unattached
to such means so as to provide a snug peripheral embrace of the insert and at the
same time insure easy insert extraction without interference.
[0007] To this end, the stuffed sealed envelope assembly is constructed according to one
embodiment of the invention with outer envelope plies secured together by means such
as a self-stick adhesive applied inwardly and outwardly of edges of the insert so
as to immobilize the insert in place without shifting relative to the plies, the insert
thereby being in contact with such adhesive but unattached thereto. The insert may
therefore be quickly and easily extracted without interference upon the removal of
an envelope stub.
[0008] A further object of the present invention is to provide such a stuffed sealed envelope
assembly containing a free insert wherein the outer envelope plies are adhesively
secured together in the customary manner along only one pair of opposite ends, the
plies being further secured together at the other pair of opposite ends thereof by
means such as self-stick adhesive applied inwardly and outwardly of adjacent edges
of the insert so as to immobilize the insert in place without shifting relative to
the plies. The insert is therefore in contact only with the self-stick adhesive but
remains unattached thereto so that it may be effectively extracted without interference
upon removal of an envelope stub.
[0009] A still further object of this invention is to provide such a stuffed sealed envelope
assembly containing a free insert wherein the outer envelope plies are secured together
in the customary manner along peripheral glue lines to form an envelope pocket for
the insert, means such as self-stick adhesive lying between the glue lines and at
least a pair of opposite edges of the insert, such means further extending inwardly
of such opposite edges for immobilizing the insert in place.
[0010] Other objects, advantages and novel features of the invention will become more apparent
from the following detailed description of the invention when taken in conjunction
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
FIG. 1 is a perspective view of series-connected envelopes constructed according to
one embodiment of the invention with a portion thereof broken away for clarity;
FIG. 2 is a plan view of an intermediate web forming insert sheets within the series-connected
envelope assemblies of Fig. 1;
FIG. 3 is a slightly enlarged plan view of an individual envelope of the Fig. 1 assembly
with the feed bands removed and being partly broken away for clarity;
FIGS. 4, 5 and 6 are sectional views taken respectively along lines 4-4, 5-5 and 6-6
of Fig. 3;
FIG. 7 is a view similar to Fig. 1 of another embodiment of the present invention;
FIG. 8 is a plan view of an intermediate web forming insert sheets within the series-connected
envelope assemblies of Fig. 7;
FIG. 9 is a slightly enlarged plan view of an individual envelope of the Fig. 7 assembly
with the feed bands removed and being partly broken away for clarity;
FIGS. 10 and 11 are sectional views respectively taken along lines 10-10 and 11-11
of Fig. 9;
FIG. 12 is a top plan view of series-connected envelopes constructed according to
yet another embodiment of the invention, parts thereof being broken away for clarity;
FIGS. 13 and 14 are sectional views respectively taken along lines 13-13 and 14-14
of Fig. 12;
FIG. 15 is a top plan view, partly broken away, of an individual envelope of still
another embodiment of the invention;
FIG. 16 is a sectional view taken substantially along line 16-16 of Fig. 15; and
FIG. 17 is a top plan view of an individual envelope, with its front peeled back for
clarity, of yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Turning now to the drawings wherein like reference characters refer to like and corresponding
parts throughout the several views, a continuous series of stuffed sealed envelope
assemblies generally designated 10 are shown in Fig. 1 as constructed of superimposed
continuous upper and lower plies 11 and 12 having spaced cross lines 13 of weakening
therein so as to respectively define envelope front and back sheets 14 and 15 (Figs.
3 to 6). Superimposed longitudinal lines 16 of weakening are provided in the upper
and lower plies near opposite edges so as to define removable feed bands having spaced
feed holes 17 therein.
[0013] A continuous intermediate web 18, shown in Fig. 2, is disposed between the upper
and lower plies and has die cuts 19 formed therein extending along opposite sides
of lines 13 of weakening. The die cuts thereby define a series of insert sheets 21
having connecting portions 22 and 23 between adjoining sheets at opposite ends of
the die cuts.
[0014] Plies 11 and 12 are respectively provided with confronting strips of securing means
24 and 25, such as self-stick adhesive, along opposing side edges thereof. Strips
26 and 27 are likewise provided on the inner surfaces of the upper and lower plies
in confronting relationship along and spaced slightly inwardly of cross lines 13 of
weakening. These strips may likewise comprise self-stick adhesive which, together
with strips 24 and 25, may be of the conventional latex adhesive which adhere on contact
or the heat sealing adhesive variety such that confronting strips will adhere only
to each other at elevated temperatures but not to the insert sheets of the intermediate
ply as will be hereinafter more fully described. Such adhesive may therefore be active
by simple contact or activated by pressure, by heat, or such self-stick adhesive may
be of the type which is activated by remoistening or the type activated by radiation.
Moreover, such confronting strips of securing means may include material such as polyethylene
which is activated upon application of heat thereto.
[0015] Strips 24 and 25 are disposed along opposite side edges 28 and 29 of inserts 21 and
are of sufficient width as to lie both inwardly and outwardly of these side edges
(Figs. 3 and 4). Likewise, confronting strips 26 and 27 of the securing means lie
along opposing end edges 31 and 32 of the inserts and are of sufficient width as to
lie both inwardly and outwardly of these end edges, as seen in Figs. 1, 3 and 5. Hence,
by the nature of such confronting strips of adhering means, strips 24 and 25 adhere
only to each other and not to any portion of the inserts along opposite edges 28 and
29. Likewise, confronting strips 26 and 27 adhere only to each other and to no portion
of the inserts along opposing end edges 31 and 32. Each insert 21, as shown for envelope
assembly 10 of Fig. 3 is thereby immobilized between the envelope front and back while
being in contact with the strips of securing means, but unattached thereto.
[0016] As in the aforementioned commonly owned '889 patent, connections 22 and 23 are severed
from the inserts during some convenient stage of the web processing operation. Such
may be carried out by cutting connections 22 and 23 along lines 33a, shown in dotted
outline in Fig. 2, so as to produce clean cuts 33. These cuts may be made through
one of the outer plies such as lower ply 12, as shown at 34 in Fig. 6, thereby serving
the dual purpose of severing connections 22 and 23 from the insert sheets, and permitting
any entrapped air within the sealed envelope assembly to escape. A completely flat
envelope assembly is therefore made possible so as to avoid the "pillowed effect"
normally occuring during the production of sealed envelopes.
[0017] Longitudinal lines 35 and 36 of weakening are respectively provided in the upper
and lower plies at one end of the envelope assemblies slightly inwardly of strips
24 and 25 of the securing means. A stub 37 is therefore produced which, upon removal,
will serve to open the envelope and extract the insert sheet. Thumb notch 38 may be
formed at lines 35 and 36 to facilitate easier grasping of the stub which overlaps
an end portion of the insert sheet.
[0018] From the foregoing it can be seen that the envelope assemblies produced according
to the aforedescribed embodiment include free inserts which are maintained in registry
between the envelope front and back without shifting relative thereto since strips
24 and 26 of the securing means respectively confronting strips 25 and 27 of the securing
means are activated when brough into contact with one another, althrough the securing
means is such that it will not adhere to any portion of the insert despite being in
contact therewith. The inserts-nevertheless remain unattached to the confronting strips
of securing means. Such an arrangement is graphically illustrated in Figs. 4 and 5
where, for purposes of the description, the inserts are shown spaced from the strips
of securing means when in fact they are in contact therewith but remain nevertheless
unattached thereto. The insert is accordingly maintained in a desired registration
position within the envelope during processing thereof through the computer printing
equipment.
[0019] In another embodiment according to the invention, a continuous series of stuffed
sealed envelope assemblies generally designated 39 are shown in Fig. 7 as constructed
of superimposed continuous upper and lower plies 41 and 42 having spaced transverse
lines 43 of weakening therein for delimiting envelope front and back sheets 44 and
45 (Figs. 9 to 11).
[0020] A continuous intermediate ply 46 is located between the upper and lower plies and
has die cuts 47 formed therein (see Fig. 8) at spaced locations so as to extend along
opposite sides of transverse lines 43. These lines are likewise provided in the remainder
of intermediate ply 46 in superimposed relationship with such lines provided in the
upper and lower plies, so as to thereby define together with the die cuts a series
of insert sheets 48 held together by connecting portions 49 at opposite ends of the
die cuts. And, superimposed longitudinal lines 51 of weakening are provided in each
of the plies along opposite longitudinal edges for delimiting feed bands 52 having
spaced feed holes 53 therein for engaging the pins of a tractor pin feed device of
web processing equipment.
[0021] The upper, intermediate and lower plies are interconnected together by means of longitudinal
glue streams 54 and 55 lying inwardly of lines 51 of weakening. As seen in Fig. 10,
these glue streams interconnect portions 49 of the intermediate ply with the upper
and lower plies. And, the upper and lower plies 41 and 42 are respectivley provided
with confronting portions 56 and 57 of securing means, such as self-stick adhesive,
along transverse lines 43 of weakening and extending between glue streams 54 and 55.
These adhesive portions are of the same type of self-stick adhesive as described earlier
with reference to securing strips 24 to 27. And, as shown in Figs. 7 and 11, such
adhesive portions are of sufficient width as to lie both inwardly and outwardly of
opposing side edges 58 and 59 of insert sheets 48. Therefore, due to the particular
characterization of confronting adhesive portions 56 and 57, they adhere only to each
other and not to any portion of the insert sheets along opposing edges 58 and 59.
And, it should be pointed out that portions 56 and 57 need not be applied in continuous
cross strips to the upper and lower plies as shown in Fig. 7, but may instead be formed
as a plurality of adhesive spots extending both inwardly and outwardly of opposing
edges 58 and 59 of the inserts, without departing from the invention. Such portions
could likewise be applied to the upper and lower plies respectively as an interrupted
longitudinal stream or as several interrupted longitudinal streams between glue streams
54 and 55.
[0022] Connecting portions 49 are severed from the inserts during some convenient stage
of the web processing operation, similarly as described for connections 22 and 23
shown in the aforedescribed embodiment. Connecting portions 49 may be separated from
the insert sheets by cutting along lines 61a, shown in phantom outline in Fig. 8,
so as to produce clean cuts 61. The severed connecting portions 49 therefore define
chip elements abutting opposite ends of the inserts for immobilizing them between
the upper and lower plies together with confronting adhesive portions 56 and 57.
[0023] Longitudinal lines 62 and 63 of weakening are respectively provided in the upper
and lower plies at one end of the envelope assemblies slightly inwardly of one of
the feed strips 52 and inwardly of the adjacent end edges defined by cuts 61 of the
inserts to thereby define a stub 64 which, upon removal, will serve to open the envelope
and extract the insert sheet. A thumb notch 65 may be formed at lines 62 and 63 so
as to further overlap the insert sheet of each assembly thereby facilitating easier
grasping of the stub.
[0024] The envelope assemblies produced in accordance with the Figs. 7 to 11 construction
include free and unattached inserts held in a desired registration position between
the fronts and backs of the envelopes by means of contacting securing portions 56
and 57 preventing the inserts from shifting longitudinally during web processing.
And, any side shifting tendency is prevented by chip elements 49, although it should
be pointed out that such side shifting is not likely to occur even without the provision
of chips 49 since the snug embrace between the inserts and securing means 56 and 57
is sufficient to maintain the insert sheets in accurate registry within the envelope
pockets of the assemblies.
[0025] In accordance with yet another embodiment of the invention, series-connected envelope
assemblies 66 are constructed similarly as described with reference to Fig. 7. Thus,
like elements will be similarly designated. As seen in Figs. 12 and 14, the upper
and lower plies are interconnected directly together by means of longitudinal glue
streams 67 lying inwardly of adjacent feed bands 52. Otherwise, these plies are further
interconnected similarly as in Fig. 7 by means of glue portions 56 and 57 respectively
provided thereon and brought into contact with one another to effect the securement.
The principle difference between assemblies 66 and 39 is that the former, as shown
in Fig. 12, have no intermediate ply as part of the construction. Instead, a series
of insert sheets 68 are disposed between the upper and lower plies and are mechanically
held in place in some desired manner until adhesive portions 56 and 57 are brought
into contact with one another. As before, such adhesive portions extend both inwardly
and outwardly of opposing edges 69 and 71 of the inserts for snugly embracing the
insert sheets to prevent longitudinal shifting thereof within the envelope pockets.
Insert sheets 68 have their opposed side edges 70 spaced inwardly of glue streams
67 completely out of contact and attachment therewith. And, since adhesive portions
56 and 57 extend between glue streams 67, confronting parts thereof extend both inwardly
and outwardly of side edges 70 to thereby prevent any side shifting of the inserts
within the envelope pockets.
[0026] In accordance with yet another embodiment of the invention, envelope assemblies 66a
are constructed similarly as assemblies 66 in Fig. 12 except that self-stick adhesive
portions in the form of adhesive dots 72 and 73 are, as shown in Figs. 15 and 16,
provided along the periphery of insert sheet 45 and extend both inwardly and outwardly
of the peripheral edges thereof. As before, when portions 72 and 73 are contacted
together they adhere only to each other and not to any portion of the insert sheet
although such adhesive portions are in contact therewith. The insert sheet is therefore
fully immobilized within the envelope pocket of the assembly. However, these spots
72 and 73 of adhesive may be provided only at opposing edges 74 and 75 of the insert
without departing from the invention. The envelope front and back 44 and 45 are further
secured together along the periphery thereof by means of continuous conventional glue
streams 76 and 77 lying outwardly of adhesive spots 72 and 73 for securing the fronts
and backs together without interruption.
[0027] Alternatively, uninterrupted lines or streams of self-stick adhesive 79 and 81 may
be applied in confronting relationship to the envelope front and back 44 and 45 along
the entire periphery of the insert 68, as shown in Fig. 17, for both securing the
outer envelope parts together and for maintaining the insert in registry therein.
Such adhesive streams, similarly as spots 73 of the Fig. 15 construction, extend both
inwardly and outwardly of the peripheral edges of the insert. Therefore, when the
self-stick adhesive streams 79 and 81 are brought into contacting relationship, the
envelope fronts and backs are secured together, the insert is brought into contact
with such adhesive lines but remains unattached thereto or to any other portion of
the envelope as a free insert in a registered position.
[0028] In positioning insert sheets 68 in place between the outer plies it may be desirable
to provide a temporary adhesive spot 78 for temporarily interconnecting the inserts
to the back sheets 45. Then, after the inserts are permanently immobilized between
the outer plies by the self-stick portions 56 and 57, as aforedescribed, the temporary
adhesive spots may be released by drying, heat, cooling, radiation, flexing, impact
or other physical or chemical changes depending on the characteristics of the temporary
glue spot.
[0029] The insert material within the envelopes of each embodiment is illustrated as single
sheets although it should be recognized that such insert material may comprise several
insert sheets, or several of such sheets including a return envelope, without departing
from the scope of the present invention.
[0030] In operation, the recipient of any envelope assembly 10, 39, 66 or 66a simply grasps
the removable stub with one hand and an opposite end of the envelope outwardly of
the opposing side edge of the insert with the other hand, and moves his hands in a
direction away from one another in a snapping action so as to cause the envelope to
be opened upon removal of the stub and simultaneously extract the insert.
[0031] Since the insert is completely unattached to any portion of the front or back of
the envelope or to any of the strips or spots of securing means, it is removed from
the envelope smoothly and efficiently without any interference. It can be seen that
care need not be exercised in disposing the strips of securing means relative to the
edges of the inserts since the self-stick feature of the securing means prevents any
adherence whatsoever with the insert.
[0032] Obviously, many modifications and variations of the present invention are made possible
in light of the above teachings. It is therefore to be understood that within the
scope of the appended claims the invention may be practiced otherwise than as specifically
described.
1. A stuffed sealed envelope assembly, comprising, superimposed front and back sheets,
insert material having peripheral edges lying within the sealed envelope, means peripherally
securing said sheets together to form an envelope pocket for said insert material,
said means to at at least one pair of opposed edges of said insert material comprising
first and second adhesive portions respectively on said sheets which adhere only to
each other to thereby secure said sheets together, said portions overlapping opposite
sides of said insert material at said opposed edges, whereby said insert material
is held captivated within the sealed envelope without shifting relative to said sheets
while being in contact with said first and second portions but unattached thereto,
and means in said sheets including a line of weakening inside said securing means
at one of said peripheral edges for opening the sealed envelope and extracting said
insert material.
2. The envelope assembly according to Claim 1, wherein said first and second portions
comprise self-stick adhesive.
3. The envelope assembly according to Claim 1, wherein said securing means at each
of said edges of said insert material comprises said first and second adhesive portions
respectively on said sheets which adhere only to each other to thereby secure said
sheets together, said portions overlapping said opposite sides of said insert material
at each of said edges.
4. The envelope assembly according to Claim 3, wherein said first and second portions
comprise self-stick adhesive.
5. The envelope assembly according to Claim 1, wherein said means at the other pair
of opposed edges of said insert material comprise first glue streams spaced from said
other opposed edges.
6. The envelope assembly according to Claim 5, wherein said first and second portions
comprise self-stick adhesive.
7. The envelope assembly according to Claim 5, wherein chip elements abut said opposed
edges of said insert material, said chip elements lying between said sheets and being
initially a part of said insert material but severed therefrom.
8. The envelope assembly according to Claim 1, wherein said means at said one pair
of opposed edges of said insert material further comprise glue streams spaced from
said one opposed edges, said first and second adhesive portions lying inwardly of
said glue streams.
9. The envelope assembly according to Claim 5, wherein said means at said one pair
of opposed edges of said insert material further comprise second glue streams spaced
from said one opposed edges, said first and second portions lying inwardly of said
second glue streams.
10. The envelope assembly according to Claim 3, wherein said securing means at each
of said edges of said insert material further comprise glue streams spaced from said
edges, said first and second portions lying inwardly of said glue streams.
11. A stuffed sealed envelope assembly, comprising superimposed front and back sheets
and an insert disposed therebetween, adhesive means securing said sheets together
at the periphery thereof including first and second securing means of like material
in confronting relationship respectively on said plies, said material being characterized
so as to adhere only to itself upon said first and second means contacting one another,
said material on each of said sheets lying both outwardly and inwardly of at least
one pair of opposing edges of said insert, said material which lies outwardly of said
edges thereby adhering to itself for securing said sheets together, said insert thereby
being held immobilized between said sheets while being in contact with said first
and second means but unattached thereto, and means in said sheets forming a removable
stub extending inwardly of said material at one of said edges for opening the envelope
upon removal and extracting the insert therefrom.
12. The envelope assembly according to Claim 11, wherein said material comprises self-stick
adhesive.
13. The envelope assembly according to Claim 11, wherein said material on each of
said sheets lies outwardly and inwardly of the other pair of opposing edges of said
insert, said material which lies outwardly of said edges thereby adhering to itself
for securing said sheets together.
14. The envelope assembly according to Claim 11, wherein said means at the other pair
of opposed edges of said material insert comprise first glue streams spaced from said
other opposed edges.
15. The envelope assembly according to Claim 11, wherein said means at said one pair
of opposed edges of said insert comprise glue streams spaced from said opposed edges,
said material lying inwardly of said dlue streams.
16. The envelope assembly according to Claim 14, wherein said means at said one pair
of opposed edges of said insert further comprise second glue streams spaced from said
opposed edges, said material lying inwardly of said second glue streams.
17. The envelope assembly according to Claim 13, wherein said means at each of said
edges of said insert further comprise glue streams spaced from said edges, said material
lying inwardly of said glue streams.
18. An assembly of stuffed sealed envelopes, comprising, superimposed upper, intermediate
and lower continuous plies respectively defining envelope fronts, inserts and envelope
backs delimited by cross lines of weakening in said plies, first and second securing
means of like material in confronting relationship respectively on said front and
back plies, said material being characterized so as to adhere only to itself upon
said first and second means contacting one another, portions of opposing side edges
of said inserts being spaced inwardly of said lines of weakening, said material on
said fronts and backs lying both outwardly and inwardly of opposing end edges and
said side edge portions of said inserts, said material which lies outwardly of said
edges thereby adhering to itself for securing said fronts and backs together, said
inserts thereby being held snuggly in place without shifting between said fronts and
backs by said material while being in contact therewith but being unattached thereto,
and means on said fronts and backs for opening the envelopes and extracting said inserts.
19. The assembly according to Claim 18, wherein said intermediate ply has connecting
portions extending between said side edges of adjacent inserts, said connecting portions
being severed from said inserts by cuts extending through one of said upper and lower
plies.
20. The assembly according to Claim 18, wherein said material comprises self-stick
adhesive.