GB2435026A

GB2435026A - Package for mailing items such as DVDs and CDs

Info

Publication number: GB2435026A
Application number: GB0702522A
Authority: GB
Inventors: Nicholas Holt; Ralph Collis
Original assignee: PSL PRINT MAN Ltd
Current assignee: PSL PRINT MAN Ltd
Priority date: 2006-02-09
Filing date: 2007-02-09
Publication date: 2007-08-15
Also published as: GB0702522D0; GB0602578D0

Abstract

A paper mail carrier formed from a web material comprises a front panel 10, rear panel 8 and, optionally, additional panel 6, the panels being connected by fold lines and further comprising at least one pocket 60 formed in or on said front and/or rear panel for receiving an item, such as a DVD. The carrier has means 12 for releasably securing the front and rear panels to retain the item in the pocket and at least one reinforcing panel (4) on said front and/or rear panel. The reinforcing panel may be adhered to the panel 8 and folded to form the pocket 60. The securing means 12 may be an adhesive flap with perforated tear lines for opening the carrier. The carrier may include means such as a further sealing flap 16 for return mailing of an item sent therein. The reinforcing panel 4 may initially have been an end part of an elongate blank forming the rest of the carrier, separable therefrom at a line of perforations. A method of forming such carriers, including printing of indicia thereon, is disclosed.

Description

Title: Improvements in and relating to packaging.

DESCRIPTION

The present invention relates to improvements in packaging, in particular to a paper packaging product for mailing articles, such as DVDs and CDs, and to a method of manufacturing such a product.

It is becoming increasingly popular to obtain rental DVDs, such as films and games, by way of ordering the DVD over the Internet. The DVD is then sent to the end user by postal mail, generally with a reply device for return of the DVD after use.

The current device for the mailing of DVDs is not ideal as it does not allow for automatic sorting of the package by barcode into postal districts nor machine sorting of the package by the postal authorities.

For example, in the UK, any bulk mailing can be eligible for postal discounts by the Royal MaiITM provided that the product conforms to certain criteria, in particular that the organisation mailing the item can perform pre-sortation functions to various degrees. The most cost effective and appropriate is Mailsort 1400TM which attracts the most discounts. The organisation preparing the mailing and sending it out have to, using proprietary software, pre-sort the address into 1400 districts, each containing a unique 5 digit numeric code, showing in the envelope. These are put into bundles, and then into labelled bags, all before the mail is collected by Royal MailTM.

This removes the need for any machine sortation by Royal MaiITM. Mail that is pre-sorted in this way does not have to conform to the same rules as unsorted mail which must go through a machine sortation process and as a result, the carrier device (i.e. the envelope) does not have to be engineered to be fundamentally any different to a normal envelope. Therefore, any party that sends out bulk mailings would wish to pre-sort the mail so as to attract discounts.

However, the DVD rental market cannot easily pre-sort mail by location due to the sequence in which the envelopes are filled being entirely dictated by the DVD title to be inserted in the package, not the delivery location. Currently, the delivery device generally used for this application is a folded pocket, glued on two short sides to form an envelope. It comprises two sides with perforations along a crease line provided just off centre of the device. One side of the device has a position on the front of it where the outgoing delivery address is personalised, (by the mailing organisation or user), by either variable inkjet, laser printing or by means of a pre-personalised address label. A tab of adhesive material also extends down the remote edge. The other side of the device has a DVD pocket for receiving the DVD, together with the address of the rental company and a strip of adhesive adjacent the central crease line. In this manner, the desired DVD, held within a plastic or paper case or sleeve, is inserted into the pocket, the sides of the device are brought together and secured by means of the adhesive tab for delivery to the customer. The customer is then able to open the envelope by unsticking the tab and opening out the device to remove the DVD from the pocket. In order to return the DVD, the side of the envelope displaying the delivery address is removed and discarded by tearing along the central perforated lines, the DVD is re-inserted into the pocket and the adhesive strip of material on the remaining side of the device is bent over and secured to this side.

This device has a number of disadvantages in that it does not allow pre-sorting by delivery address nor sorting by the postal authority, due to the thin nature of the envelope resulting in it being too fragile to pass through mechanical sortation equipment as it would allow damage to the DVD and the fact that the folder is only secured along two sides thereof. Clearly, it would be desirable to provide a paper envelope or carrier that would allow sorting of bulk mailings by the postal authority by means of their machine sortation processes to enable the product to be eligible for postal authority discounts. This would relieve the heavy burden placed on postal authorities, such as Royal MailTM due to the need to hand sort such deliveries which are rapidly increasing in demand. Furthermore, mail carriers that are sealed around all sides, and comply to certain sizing, can quality for bulk, machine sortable discounts, such as CleanmailTM, Cleanmail PlusTM, and Response PlusTM of Royal MaiITM.

It is an object of the present invention to provide a mail carrier, particularly but not exclusively for the postal delivery of a DVD or CD, that may be sorted by means of a machine sortation process.

A further object of the present invention is to provide a method of manufacturing a mail carrier, such as a paper envelope, that may enable the carrier to be manufacturcd quickly and cheaply compared to the prior art.

Accordingly, a first aspect of the present invention provides a paper mail carrier formed from a web material, the carrier comprising a front panel and a rear panel, said front and rear panels being connected by fold lines and further comprising at least one pocket formed in said front andlor rear panel for receiving an item, means for releasably securing front and rear panels to retain the item in the pocket and further comprising at least one reinforcing panel on said front and/or rear panel.

The postal mail carrier according to the first aspect of the present invention is formed from a web material, i.e. it is a reel-fed, web-finished carrier wherein the product (roll or web of pre-printed paper) remains on a reel until final cross cuts are made to separate and arrange it into individual carriers.

The substrate for making the carrier is a paper-based product. It may comprise paper on reels, woodfree, part-mechanical, or recycled, finished uncoated, gloss, silk or mart art coated. Preferably, the substrate is a maximum of 200 gsm (grams per square metre), more preferably being in the range 135-170 gsm.

The finished carrier may be any suitable size depending upon the article to be contained within the carrier andlor the requirements of the postal authority for sorting by means of a machine sortation process. Preferably, the carrier is in the range from 124mm x 173mm to 165mm x 240mm.

Preferably, the front andlor rear panel of the carrier is provided with a single reinforcing panel. Alternatively, one or both panels may be provided with two or more reinforcing panels secured thereto, depending upon the degree of rigidity required in the finished product. More preferably, a single reinforcing panel, preferably being substantially the size of the sum of the front and rear panels, is adhered to the intended inner surface of both the front and rear panels. The reinforcing panel of the front and/or rear panel may be secured to the intended inner surface of the panel in such a manlier as to form a pocket. For example, a strip of adhesive may be provided along a top and bottom edge of the reinforcing panel which is then secured to the front or rear panel to form a pocket for receiving an item, such as a DVD or CD, between the strips of adhesive. Alternatively and more preferably, a pattern of adhesive may be provided on one side of the reinforcing panel which is then secured to the front or rear panel to form a pocket for receiving an item between the pattern of adhesive.

In an alternative embodiment, a reinforcing panel may be folded over on itself and secured along its sides to form a pocket, the panel being secured to the front or rear panel to form both the reinforcement and the pocket.

It is envisaged that the CVD or DVD will be provided in a synthetic envelope made from TyrekTM or other similar synthetic paper product for insertion into the product.

As mentioned, the reinforcing panels may be folded over and secured to the front and rear panel and/or may be cut and pasted to the front and/or rear panel. In one embodiment of the present invention both the front and rear panel is provided with a single reinforcing panel attached thereto which is cut away and laid over the front or rear panel and secured thereto to form a double thickness layer.

Preferably, at least one flap is provided for securing the front and rear panels together in the assembled carrier. Preferably, the flap is provided with a strip of adhesive material and/or a varnished paper strip to be peeled away to expose the adhesive to allow sealing. In addition, a double line of parallel perforations are preferably provided to facilitate re-opening.

It is to be appreciated that a combination of creases and perforations may be applied to the web material, as appropriate, to facilitate folding of the panels and flaps as required to form the carrier.

ifl a preferred embodiment of the pieseiit iiiveritiun the carrier is provided with an additional main body forming panel connected by fold lines to the front or rear panel, the panel being substantially the same dimensions as the front and rear panels.

This main body forming panel is preferably provided with the sealing flap thereby forming a wrap-around panel for wrapping around the front panel and sealing to the rear panel by means of the sealing flap in the closed device.

It is preferable that the carrier includes means for return mailing of the item sent therein. In this respect, it is preferable for the panel having the pocket to be detachable from the adjacent panel so that the pocketless panel may be discarded.

The panel having the pocket is preferably provided with an additional flap having means for securing the flap to the panel for re-closure of the carrier for return delivery, for example in a similar manner to the construction of the outgoing sealing flap.

It is to be appreciated that the carrier should be provided with a position on a front panel of the outgoing device where the outgoing delivery address may be applied by the user, such as by the way of variable inkjet printing, laser printing or by applying a prepersonalised address label. Similarly, a similar position should be provided on a panel of the return delivery portion for application or display of a return delivery address.

In a preferred embodiment of the present invention, the web material forming a single carrier comprises, in a single line in the web direction, a single reinforcing panel, preferably being dimensioned to at least partially cover both a front and rear panel of the carrier, a return sealing flap, a front and rear panel and a delivery sealing flap. Optionally, an additional main body forming panel may be provided in line with the front and rear panels. Each sealing flap is preferably provided with a strip of adhesive and optionally, a zip opening formed by two parallel lines of perforation.

Preferably, the reinforcing panel is cut away from the adjacent front and/or rear panel and is secured to one or both panels to reinforce the panels. Preferably, the reinforcing panel is only partially secured to one of the panels thereby forming a Ti, 41 C...-J.. ......C....... A * .. -r,r -poc1.t. ajie urn iiap AU.IIU) LIA.dLIU1L1. i-ii itcui Uit aS a LI V U VI 1J flay then be inserted into the pocket and the front, rear and further panel folded over and secured by means of the delivery sealing flap being folded over and glued thereto.

In an alternative embodiment, the web material forming a single carrier comprises, in a single line in the web direction, two reinforcing panels, a return sealing flap, a front and rear panel, a further panel and a delivery sealing flap. The reinforcing panels are cut away from the adjacent front or rear panel, folded together and secured to each other and then partially secured to a front or rear panel to form the pocket.

The carrier further comprises lines of weakness, such as a line of perforations, provided between the front and rear panels whereby the two panels may be disconnected. In this manner, the panel with the pocket and double thickness layer can form the return portion, having the return sealing flap folded over the opening of the panel and secured thereto by means of the adhesive.

In a preferred embodiment of the present invention, a strip of cohesive glue is applied to each outer edge on the intended outer surface of the rear panel or front panel and to each outer edge of the intended inner surface of the front/rear panel or additional main body forming panel, depending upon whether the latter is included in the carrier. Each strip is preferably the entire length of the panel, less the depth of the return flap, and the cohesive nature of the adhesive results in the strips being inert until a pair are mated together wherein they stick together sufficiently to close the piece but not so aggressively that they tear the paper when opened. Thus, when the carrier is folded closed, the two pairs of adhesive strips mate to form a re-peelable closure, resulting in all four sides of the carrier being closed far mailing. This is advantageous as mail carriers that are sealed around all sides may qualif' for bulk mechanised mail postal discounts, such as CleanmailTM, Cleanmail P1usTM, and Response PIUsTM of Royal MaiITM.

Alternatively, if the product is delivered completely folded to the mailing organisation, before insertion otthe disc and addressing for mailing, the glue may be a low tack adhesive style, such as "post-it note" glue, in which it is applied to each open edge of one panel only, rather than to two opposing panel edges as required with cohesive glue.

It is to be appreciated that the carrier according to the present invention is formed from a web finishing process which may assemble the carrier in or off-line.

To this end, a second aspect of the present invention provides a method of manufacturing a mail carrier comprising the steps of: printing onto a reel of paper, said printing including the application of at least an undeliverable or reply address and/or technical print marks; delivering the printed paper to a finishing line for the creation of a plurality of carriers from a plurality of blanks, said finishing line including the steps of removing and/or folding outer ribbons provided at at least one end of each blank to overlay a front and/or rear panel formed between the ends of a blank; applying adhesive and lines of weakness to parts of the blank; and folding the parts of the blank to form a mail carrier.

Preferably, the application of adhesive includes a cohesive adhesive, preferably being applied at the free outer edges of the front and rear panels but on opposing surfaces of the panels.

It is to be appreciated that the steps carried out in the finishing line may be carried out in any order but preferably the removal and/or folding of the outer ribbons to overlay a front andlor rear panel is carried out first in the line. The ribbons form reinforcing panels in the mail carrier. Preferably, at least one of the reinforcing panels is only secured to its respective front or rear panel by two parallel strips of glue or other securing means at opposing edges of the panel to form a pocket for receiving an item. Alternatively, if two reinforcing panels are secured together, these panels may only be secured in this maimer to form the pocket for receiving an item.

It is to be appreciated that the steps carried out in the finishing line may be carried out in any order but describing here the off-line process, where the printed images and spot and release varnishes are applied first by a web printing press, and the printed reels are offered to the finishing line, any perforations or creases are preferably applied first, then flaps are treated with permanent glue, over which a narrow section of the web, carrying varnish, is folded over and trimmed to form the peel-off adhesive portion of each flap. Preferably, the ribbon is then detached from the web, brought down and glued to the front and/or back panels which will form the outer layers of the pocket, then folded and pattern glued to form the pocket. Strips of cohesive glue may then be applied to both open edges of the face of the rear panel and the opposing open edges of the other panel (i.e. front or additional panel) before finally being cut to single carriers at the delivery end of the finishing line.

The printing process may be in-line or off-line with the finishing line, preferably being off-line. The printing process may comprise, for example, rotary offset lithography, (preferably 1-6 colours on both sides of the paper) and UV or aqueous spot varnish. The printed matter may be heatset or UV dried.

Technical marks may be printed onto the web material to show, for example, boundaries, due, fold and/or perforation positions.

Any suitable adhesive may be used for gluing the layers of the paper together, such as solvent or emulsion-based, permanent and/or peelable simple or cohesive adhesives. Alternatively, a latex gummed solvent, re-moistenable glue or proprietary tape-seal may be used, preferably incorporating finger-lift tape, supplied on reels.

Preferably, varnish is applied adjacent any glued region to prevent the glue sticking to the paper. Preferably, the sealing flaps of the carrier are finished by means of applying permanent glue strips to the flaps, folding the flaps (preferably with varnish applied) to lay over the aforesaid strips, the flaps having 2 parallel patterned perforations provided alongside. The fold edges are preferably trimmed off, allowing the carrier or its return portion to be sealed by removing the strip, revealing the glued flap which seals the envelope. The envelope may be re-opened by zipping open the patterned perforations.

Optionally, the carrier according to the present invention may include one or more window shapes, preferably being die cut through one or more panels of the carrier and protected by clear film, such as acetate, glassine or similar, which is secured by gluing around all sides of the window. The window may enable the viewing of an address for mailing, from an insert to the mailer, or a barcode or other identifying information for purposes of recognition by the mailing organization.

For a better understanding of the present invention and to show more clearly how it may be carried into effect reference will now be made by way of example only to the accompanying drawings in which: Figures la and lb are front and back plan views of a web material illustrating the parts for forming a single postal mail carrier according to one embodiment of the present invention; Figures 2a to 2d illustrate schematically the steps involved in finishing the mail carrier shown in Figures la and Ib; Figures 3a and 3b are front and back plan views of a web material illustrating the parts for forming a single postal mail carrier according to a second embodiment of the present invention; Figures 4a to 4g are schematic perspective views of an assembled postal mail carrier according to the present invention, illustrating its various formats for use; Figures 5a and 5b are front and back plan views of a web material illustrating the parts for forming a single postal mail carrier according to a third embodiment of the present invention; and Figures 6a and 6b are front and back views of a web material illustrating the parts for forming a single mail carrier according to a fourth embodiment of the present invention.

Referring to the accompanying drawings, various types of blank for forming a carrier according to the present invention are illustrated. The drawings show a single blank of paper but in reality a large number of repeated blanks would be provided end to end on a reel or web of material which is subject to a printing process and subsequently cut, folded and pasted to form a plurality of individual carriers.

Furthermore, the boundaries of the various sections of the blank would not in fact be visible but be provided by means of technical marks preprinted to show boundaries, glue, folds and/or perforation positions.

It is to be appreciated that any desired information may be printed onto the front or rear of the reel of paper, but typically includes postage paid impression, return address and/or an advertising logo, for example, of the supplier. The printing process may be conducted on or off-line with the finishing process which forms the carrier from the reel of paper. Varnish may also be applied to the paper reel during the printing stage, for example at regions of the paper which will be adjacent to glued regions. The printed matter may be heatset or UV dried.

The finishing line processes the printed paper into a carrier by dividing each blank into a number of panels and strips. In its most basic form, the carrier is comprised of central panels and strips that form the outer part of the assembled carrier and means for securing the panels together respectively but additionally, the blank is provided with at least one additional reinforcing panel or ribbon at one or both ends of the blank which may be separated or folded over the remaining panels of the blank to form a carrier with at least one double thickness.

For example, Figures Ia to 2c of the accompanying drawings illustrate the format of a mail carrier according to one embodiment of the present invention. Each blank has a front (outer surface) and back (inner surface) view, illustrated by Figures ) Ia and lb respectively, and is divided into a number of reinforcing panels 4 (x2), main panels 6, 8,10 and smaller strips of material 12, 14, 16, 18 that are capable of being assembled into a mail carrier by way of various cuts and folds being performed on the blank, as described in further detail below.

The embodiment shown in Figures Ia and lb has a strip 12 (for example 50mm x 210mm) which is provided with a line of weakness 30, for example, in the form of a line of perforations, and a strip of adhesive 32 (such as a permanent glue strip, re-moistenable glue or a proprietary tape seal) extending transverse to the longitudinal direction of the blank/reel, This is connected to a further strip 14 (for example, being 41mm x 2 10mm) that is connected to a main panel 6 (eg. 132mm x 2 10mm). This panel contains an area 20 to be used for the delivery address (applied by the mailing organisation or user of the product). Alternatively, this box may in the form of a transparent window or transparent flap for displaying the address from an inserted letter. The panel 6 is connected to main panel 8 (eg. 130mm x 210mm) that in turn is connected to main panel 10 (eg 127mm x 210mm), the panels being separated by means of fold or crease lines. Two further strips 18, 16 of the same dimensions as strips 12, 14 are provided adjacent panel 10 and finally two reinforcing panels 4 adjoin strip 16.

As mentioned, the aforementioned blank is provided on a single reel which may be slit to create ribbons detached from the main web. In Figures Ia and 1 b, panels 4 can be slit by appropriate machinery to provide ribbons which can be shifted, folded (where applicable) and brought down and glued to the panels 8 or 10 of the main web. Figures 2a to 2c of the accompanying drawings illustrate the finishing of the carrier from the blank in further detail. The end reinforcing panel 4 is folded over its sister panel 4 and sealed thereto along the head and foot only by means of a suitable adhesive 70, (as shown in Fig. 2a), the double layer is then cut away from strip 16 (see arrow S) and laid over and secured to the panel 8 (as illustrated by arrows A in Figure 2a). Sealing the panels 4 together at the head and foot only provides a central section 60 between the secured areas that is wide enough to receive the item to be held within the carrier, such as a DVD or CD. However, it is to be a) appreciated that the two panels 4 could be secured completely together and then only attached to panel 8 at the head and foot thereof to provide the required pocket. The strip 16 is folded back towards the panel 10, as shown in Figure 2a.

It is to be appreciated that further reinforcing panels could be provided if required, for example by providing another panel at the other end of the blank which may be slit from the rest of the blank and brought down and glued onto a main panel (not shown).

It should be noted that at this stage the reinforcing panels or ribbons remain in continuous (reel) form when slit away from the main web and are guided, through a system of rollers, back down to the main web to be secured to the main panels.

Figure 2b of the accompanying drawings illustrates the form of a single carrier once the reinforcing panels 4, 4 have been attached to the main panel 8. Strips 16 and 12 are both folded inwardly towards their adjacent panels 10 and 6. The panels 4, 4 which have been glued to each other (head and foot) so as to fit a DVD or CD into it, are folded a few millimetres off course so as to easily accept the DVD/CD.

Figure 2c illustrates the form in which the carrier is presented to a customer (e.g. DVD rental organisation). Panel 10 is brought down over panels 4, 4, 8 (as indicated by arrow C in Fig. 2b) and glued together. It is then possible to insert a DVD/CD between the two reinforcing panels 4 sandwiched between panel 8 and panels 10. Panel 6 is then taken right over the reinforced panels containing the DVD and glued down by flap 12 (see Fig. 2c).

The multiple thickness panels strengthen the carrier and protect the DVD or other item contained therein. This enables the carrier to be strong enough to withstand the rigours of high speed sortation equipment and thick enough to avoid the edges of the DVD creating a ridge in the surface of the envelope/carrier. Furthermore, the nature of the carrier is such that it is still able to bend to the required degree to enable it to move through the sorting machinery.

Once the carrier reaches its destination the customer is able to open the envelope by slitting it along the strip 12, unfolding the reinforced panels from panel 6 and removing the DVD or other item from the storage section. In the embodiment illustrated in Figures la to 2d, the carrier includes a return delivery portion for returning the item after use. The carrier is separated along a line of weakness 40 provided between panels 6, 8. Panel 6 is then discarded along with the strips 12, 14 and the DYD or other item is placed back in the storage section 60. The strip 16 then folded outwardly to close the opening between panels 10, 4 and 4, 8 and secured to the back of panel 8 by means of the adhesive 42. A return address 24 is provided on the panel 6 or 10.

Panels 8 and 10 may each be provided with a transparent window to display information from an inserted letter, such as return address or a barcode or number on the contents of the envelope.

Figure 2d illustrates in further detail one way of opening and closing the device by means of the sealing flaps. Strips 12, 14 and 16, 18 are provided with a line of varnish 80, a zip opening 82, a fold 84, a glue line 86. Each set of adjacent strips (16, 18 and 12, 14) is folded along the fold 84 to create a double thickness strip (see Figure 2b). The fold is trimmed off along cut lines c-c (as close as possible to it), leaving the varnished strip 80 sitting un-attached to the glued area 86, held to it by means of the glue alone. To use, the face strip is peeled away, exposing the glue line.

This flap is then folded to the back of the envelope to seal. To open, the user tears along the perforations of the zip opening 82.

It is to be appreciated that the strip 16 could be omitted from the blank to provide a carrier without a return delivery portion. However, an essential feature of the present invention is that the blank is reel fed and that parts of the blank are slit away to form ribbons that aresuperimposed and stuck on the panels of the carrier to reinforce the same.

Figures 3a and 3b illustrate a blank for forming a mail carrier according to another preferred embodiment of the present invention. Identical features to those already described in relation to Figures Ia and lb are given the same reference numerals. Figure 3a shows the intended outer surface of the carrier and Figure 3b shows the intended inner surface. The orientation shown in Figures 3a and 3b is the preferred orientation for the web finishing line. The blank again has two reinforcing panels 4',4", main panels 6, 8, 10 and smaller strips of material 12, 14, 16, 18 but the reinforcing panels are created as a single panel. The reinforcing panel 4,4 (for example, 270mm x 210mm) is joined to a strip 16 (for example 50mm x 210mm) which is provided with a line of weakness 30 where it connects to strip 18 (for example, being 41mm x 2 10mm) which contains a double parallel line of perforations, and a strip of adhesive 32 (such as a permanent glue strip, re-moistenable glue or a proprietary tape seal) extending transverse to the longitudinal direction of the blank/reel. This is connected to a main panel 10 (eg 135mm x 210mm) containing an area 20 to be used for the delivery address. This panel contains two strips of cohesive glue 100 and is connected to main panel 8 (eg 135mm x 210mm) that in turn is connected to main panel 6 (eg 136mm x 2 10mm), the panels being separated by means of fold or crease lines. Main panel 6 also contains two strips of cohesive glue 100 on the opposing side to the main panel 10. Two further strips 14, 12 of the same dimensions as strips 16, 18 are provided adjacent to panel 6.

As mentioned, the aforementioned blank is provided on a single reel which may be slit to create ribbons detached from the main web. In Figures 3a and 3b, panels 4',4" are slit as a single reinforcing panel by appropriate machinery to provide a ribbon which can be shifted and brought down and glued to the panels 8, 10 of the main web, thereby reinforcing both panels 8, 10.

In order to further explain the functionality of the paper mail carriers as described in Figures la to 3b, Figures 4a to 4g of the accompanying drawings illustrate the carrier in use, showing singles of the product, having been cut from the continuous web, being the final action on the finishing line.

Figure 4a illustrates the constructed carrier, as it would normally be presented to the mailing organisation, the bulk customer (eg DVD Rental organisation) and depicts a DVD 200 half inserted into the double thickness pocket 202. Figure 4b shows the strengthened pocket, complete with inserted DVD, being folded onto the inside of the outgoing panel 204 (described, in Figures Ia and lb as panel 6). Figure 4c illustrates the device, now folded closed, with the outgoing sealing flap 206 (12 in Figures 1 and 2) in the process of having the cover strip removed. Once removed, it is offered to the reverse of the pocket, to seal through activation of the permanent glue strip. The pocket is now closed with all four sides stuck down through activation of the two pairs of cohesive glue strips (not visible in Figure 4) which mate and adhere together on contact.

Figure 4d shows the device, sealed down, with the two parallel lines of perforations 208 (described as 82 in Figure 2d) being partially lifted, as a zip opening, demonstrating how it would be opened by the recipient. The DVD or similar is removed by allowing the panel 204, having been released through the zip opening process, to fold back. Figure 4e depicts the panel 204 being removed, either along a perforation, as shown, or alternatively a crease may be provided to allow it to be torn away, or a dotted line, as a cutting guide for scissor cut., in preparation to be used as a return device (see Figure 41) The pocket 202 has the disc re-inserted, and the return flap partially activated through the peeling away of the cover strip 210 exposing the glued flap 212. Figure 4g depicts the device, as it would be received, having been returned to the mailing organisation (eg DVD Rental company). This can then be opened by peeling away parallel perforations, as a zip opening, or these perforations can be omitted, allowing the device to be simply ripped open, to access the contents.

The provision of blanks provided with two strips of cohesive glue 100 near the free edges of each of panels 6 and 10, i.e. adjacent to the head and foot of the return envelope face and the short edges of the long address panel, as shown in Figures 3a and 3b enables the carrier to be sealed along all sides. Each strip is preferably at least 25mm in length and the cohesive nature of the adhesive results in the strips being Th inert until a pair are mated together wherein they stick together sufficiently to close the piece but not so aggressively that they tear the paper when opened. Thus, when the carrier is folded closed, the two pairs of adhesive strips mate to form a re-peelable closure, resulting in all four sides of the carrier being closed for mailing. This is advantageous as mail carriers that are sealed at least partly around all sides may qualify for further postal discounts, such as CleanmailTM and Cleanmail PlusTM of Royal MailTM.

Figures 5a and 5b illustrate yet a further embodiment of the present invention.

Again identical features to those already described in relation to Figures Ia and lb are given the same reference numerals and only the differences will be discussed in detail.

The blank omits panel 6 and strips 16 and 18 such that the panels 4,10 are folded Onto the panel 8 which is then sealed by means of the strip of material 12. Thus, this embodiment is an example of a double thickness, one-way device.

Figures 6a and 6b illustrate a further blank which corresponds to that shown in Figures 3a and 3b but where the return flaps are again omitted, to make a one way device, with no facility for return, but with the outgoing additional panel 6 remaining to provide a long wrap-around outward flap/panel which provides valuable space for advertising or the like.

It is to be appreciated that any suitable means may be provided for sealing the carrier and/or the return portion thereof. In a preferred embodiment of the invention, permanent glue strips are applied to the flaps which are plowfolded with varnish applied, to lay over the glue strip, with 2 parallel patterned perforations alongside.

The fold edges are trimmed off, allowing the envelope/reply envelope to be sealed by removing the strip, revealing the glued flap, which seals the envelope. The envelope is re-opened by zipping open the pattern perforations. Th

Claims

CLAIMS

1. A paper mail carrier formed from a web material, the carrier comprising a front panel and a rear panel, said front and rear panels being connected by fold lines and further comprising at least one pocket formed in said front and/or rear panel for receiving an item, means for releasably securing front and rear panels to retain the item in the pocket and further comprising at least one reinforcing panel on said front Il -. 1 -anuiur rear panel.

2. A paper mail carrier as claimed in claim 1 wherein the front and/or rear panel of the carrier is provided with a single reinforcing panel.

3. A paper mail carrier as claimed in claim 2 wherein a single reinforcing panel, being substantially the size of the sum of the front and rear panels, is adhered to an intended inner surface of both the front and rear panels.

4. A paper mail carrier as claimed in claim 1, 2 or 3 wherein the reinforcing panel of the front and/or rear panel is secured to an intended inner surface of the front and/or rear panel in such a manner as to form a pocket.

5. A paper mail carrier as claimed in claim 4 wherein a strip of adhesive is provided along a top and a bottom edge of the reinforcing panel which is then secured to the front or rear panel to form a pocket for receiving an item.

6. A paper mail carrier as claimed in claim 1 wherein a reinforcing panel is folded over on itself and secured along its sides to form a pocket, the panel being secured to the front or rear panel to form both the reinforcement and the pocket.

7. A paper mail carrier as claimed in any one of claims I to 6 wherein at least one sealing flap is provided for securing the front and rear panels together in the assembled carrier.

8. A paper mail carrier as claimed in claim 7 wherein the flap is provided with a strip of adhesive material and/or a varnished paper strip to be peeled away to expose the adhesive to allow sealing.

9. A paper mail carrier as claimed in claim 7 or 8 wherein a double line of parallel perforations are provided to facilitate re- opening of the flap.

10. A paper mail carrier as claimed in any one of the preceding claims wherein (he carrier is provided with an additional main body forming panel connected by fold lines to the front or rear panel, the panel being substantially the same dimensions as the front and rear panels.

11. A paper mail carrier as claimed in claim 10 when dependent from claims 7 to 9 wherein the additional main body forming panel is provided with the sealing flap thereby forming a wrap-around panel that wraps around the front panel for sealing to the rear panel by means of the sealing flap.

12. A paper mail carrier as claimed in any one of the preceding claims wherein the carrier includes means for return mailing of an item sent therein.

13. A paper mail carrier as claimed in claim 12 wherein the panel having the pocket is detachable from the adjacent panel so that the pocketless panel can be discarded and the panel having the pocket is provided with an additional sealing flap having means for securing the flap to the panel for re-closure of the carrier for return delivery.

14. A paper mail carrier as claimed in any one of claims 10 to 13 claims wherein each outer edge on the intended outer surface of the rear panel or front panel is provided with a strip of cohesive glue, as is each outer edge of the intended inner surface of the frontJrear panel or additional main body forming panel, depending upon whether the latter is included in the carrier.

15. A paper mail carrier as claimed in claim 14 wherein each strip is the entire length of the panel, less the depth of a return flap.

16. A web material for forming a single paper mail carrier comprising in a single line in the web direction, a single reinforcing panel, the panel being dimensioned to at least partially cover both a front and rear panel of the carrier, a return sealing flap, a front and rear panel and a delivery sealing flap.

17. A web material as claimed in claim 16 wherein an additional main body forming panel is provided in line with the front and rear panels.

18. A web material as claimed in claim 16 or 17 wherein each sealing flap is provided with a strip of adhesive and a zip opening formed by two parallel lines of perforation.

19. A web material as claimed in claim 16, 17 or 18 wherein the reinforcing panel is cut away from the adjacent front andlor rear panel and is secured to one or both panels to reinforce the panels.

20. A web material as claimed in claim 19 wherein the reinforcing panel is only partially secured to one of the panels thereby forming a pocket.

21. A web material as claimed in any one of claims 16 1020 wherein the return flap extends freely therefrom.

22. A web material for forming a single paper mail carrier comprising, in a single line in the web direction, two reinforcing panels, a return sealing flap, a front and rear panel, a further main body forming panel and a delivery sealing flap.

23. A web material as claimed in claim 22 wherein the reinforcing panels are cut away from the adjacent front or rear panel, folded together and secured to each other and then partially secured to a front or rear panel to form the pocket.

24. A web material as claimed in any one of claims 16 to 23 further comprising lines of weakness, such as a line of perforations, provided between the front and rear panels whereby the two panels may be disconnected.

25. A method of manufacturing a mail carrier comprising the steps of: printing onto a reel of paper, said printing including the application of at least an undeliverable or reply address and/or technical print marks; delivering the printed paper to a finishing line for the creation of a plurality of carriers from a plurality of blanks, said finishing line including the steps of removing and/or folding outer ribbons provided at at least one end of each blank to overlay a front and/or rear panel formed between the ends of a blank; applying adhesive and lines of weakness to parts of the blank; and folding the parts of the blank to form a mail carrier.

26. A method according to claim 25 wherein the removal and/or folding of the outer ribbons to overlay a front and/or rear panel is carried out first in the line.

27. A method according to claim 25 or 26 wherein the ribbons form reinforcing panels in the mail carrier.

28. A method according to claim 27 wherein at least one of the reinforcing panels is only. secured to its respective front or rear panel by two parallel strips of glue or other securing means at opposing edges of the panel to form a pocket for receiving an item.

29. A method according to claim 27 wherein two reinforcing panels are partially secured together in a manner to form the pocket for receiving an item.

30. A method according to any one of claims 25 to 29 further comprising applying a varnish adjacent any adhered region to prevent the adhesive sticking to the paper.

31. A method according to any one of claims 25 to 30 further comprising applying strips of cohesive glue to both open edges of the intended outer surface of the rear panel and the opposing open edges of the other panel, being a front or an additional panel.