CA2142732C - Single-part statement mailer - Google Patents

Abstract

A single ply of paper in web form continuously forms one-piece statement mailers by first die-cutting appropriate portions of the mailer to form a window (38) for a return envelope, and inset edges for bang - tail and payment coupons (17, 13). Non-personalized and personalized information is printed on the single ply on various panel. By repeating sequences of applying glue and folding the web into various panels, a complete statement with personalized and non- personalized information can be provided an addressee. Additionally, fugitive glue lines (52) are provided in the return envelope to space the inserts, i.e., a payment coupon and remittance, from edges of the return envelope to facilitate opening of the envelope by automatic mail openers.

Description

W~ 95/01917 .. ~ ~ ~ ~ ~ J ~ PCT/hi1TS94/07529 .
. _ ~ .

SINGLE-PP.RT S~'AZ'' MAILER
TECENICAh FIELD

The present invention. relates to a single-part statement formed of a single ply folded to form panels which are adhered together to farm a mailer, including an outgoing a mailer; a business return envelope, a payment coupon and a statement, as well as ~o methods for forming such mailer.

The present' invention also relates to a mailer having a return envelope constructed to locate material inserted into i the return envelope spaced from the margins of the return envelope sufficiently to permit the use of automatic' high-sg~ed letter openers without cutting or otherwise t, damaging the inserts: Further; the present invention ;, provides a'single-part statement capable of re~eizring one or 3,: more loose inserts within the panels of the mailer.

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;;; Statements, for example, credit card-statements, as well as other types of business forms, are typically produced,by printing a tatement and inserting the statem~nt,,togethen with a separate return envelope, into an outgoing envelope. Thus, three separate pieces, an outgoing mail envelope, a business return envelope and the statement itself; ale used. Personaii~ed information is normally t e r '' ' ~

~~~ ' s n s, paym statemei~a, such as account ziumbe ri:nted on the~
p due, etc., and an the outgoing envelope. Portions of all three parts are also printed with non-personalized generic infanx~ation, such as adve=using information, the name and address of the company-forwarding the statement, identifiers for the personalized information and other information.

Separate processes and processing are required to print and collate statements of this type and this, of course, involves substantial costs. It has been found highly i . , WU 9511917 ~ ' PCTIUS94/07529 '~32 desirable to farm a single-part statementincorporating into a single-paper ply an outgoing mailing envelope, the statement ztself, a payment coupon, if applicable, and a return envelope for the statement. Further, all necessary personalized information may be printed on the various panels of the single ply prior to folding and securing the panels to one another to form an outgoing mailer.
Additionally; it is frequently desirable to provide loose inserts in the outgoing mailer for review and use by the recipient.
Still further, one of the many problems when using a return envelope containing a remittance or payment coupon, or both, is that, for h~:gh-volume mailers, high-speed letter openers are typ~:cally used to open the return envelopes.
These openers typically cut off the top and side margins of the envelops ire order to open tl~e return envelope on three sides end enabla extraction 4f i"ts contents. Most openers are set, to cut or slit at a di.stanc~e approximately 1/64-inch fr~m the sides and top of the envelope. However, in using the present mailer, the openers are preferably set at 1/4 inch to: ensure complete removal of the marg~.nal stubs of the .
return enveloge. Glue systems for mailers and return envel~pes, however, are not capable of controlling the width i of glue strips or end seams within high tolerances.
i Ordinara.ly, the width of the glue on one side will vary substantially, for example; between .06 inches and .18 '' Finches: As'a consequence, the inserts, such as a rem~.ttance and accompanying payment coupon, frequently tend to orient themselves toward one side of the return envelope and not infrequently are cut during the automatic mail opening process. These-inserts; once removed from the envelopes, are normally read automatically by an optical system. Thus, a,ny damage to the insert caused by opening the envelope makes the insert oftentimes unreadable by the optical system, necessitating further processing of the insert by ,.., .
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DISCIaOSl'3R,E OF THE INVENTION
Tzz accordance with the present invention, a single-paper ply in web farm ~.s divided into a series of panels and foldline . The web is then folded and the panels adh_Bred to one another by adhesi~re .in alternating steps. Thus, after personalized arid non-personalized information are imaged or ;printed on one or both sides of the ply and the single ply is'die-cut; adhesa.ve is applied to one or both (depending upon th.e nature of the adhesive) of first and second panels which will force a return envelope in each mailer. The 'continuous ply is subsequently folded to register and adhere those panels to one another; thus forming the return envelop: After the first folding, and in a first embodiment hereof, adhesive is applied to one or both of the second and fifth panels; with the ply being subsequently folded to. register and adhere the second and fifth panels one o the othex'e Adhesive i~ then applied to the first and fourth paxaels. Subsequently; th.e ply is folded about registering fourth and third foldlines to register the third and fourth p~nel~ with the ~irs~; second and fifth panels and~adhex°e the f~rstand;fraurth panels to one another.
Adhesive is then applied to the fourth and sixth panels whereupon they are subseguently folded about a fifth 'foldline and adhered to one another, completia~g the mailer.
,i , ~ , ., In ~ second embodiment hereof, the first 'and second 'panels are folded to form the return envelope similarly as described above in c~nnection wi h the first embodiment. At this st~.ge of the mailer forming process, however, the marga:ns of ahe'first and second panels are die-cut substantially parallel to or slightly inset from the locations of the lines of perforations which will form the tear strips in other parcels of tha complete mailer.
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i Additionally, the next or second foldline 'is located between 1 i the return envelope flap and the top of the first panel. In ' the formation of the mailer of this second embodiment, the registering first and second panels are folded about the ' second foldline into re istration with the third anel g p ' i.e., the payment coupon. At this stage, all edges of the first, second, third and seventh panels are either parallel with or inset from the lines of perforations forming the tear strips in the completed mailer. The registering first, second, third and seventh panels are then folded over a j third foldline td overlie the fourth panel Adhesive is then applied to one o~ the fourth and fifth panels in the margins thereof to secure the fourth and fifth panels to one another when the first through fourth and seventh panels are folded about a fourth faldline into registration with the fifth pane.. Adhesive is t~xen applied to the margins of the fourth or sixth panel and the panels folded about a fifth foldline to form the completed mailer.
Tn this second embodiment, it will be appreciated that the edges of the return envelope do not carry tear strips and that they are perf~ctlyforened in the production of the mailer. Thus, frayed or ragged edges resulting from inadequate tearing of the tear strips by the recipient of the mailer are avoided, thereby facilitating alignment of the return envelope in automatic mail opening machinery.
Also, by locating the second foldline between the top of the return envelope and the return envelope flap, there is provided a scoreline about which the return envelope flap may be folded. This avo~.ds skewing of the flap during sealing and facilitates proper sealing thereby also affording proper alignment of the return envelope in the automatic mail opening machinery.
In the foregoing process, the adhesive is preferably a cold glue applied in spots to one of the panels to be Z
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a adhered together, although it will be appreciated that other ' types of adhesive, for example, hot melts, and other types of adhesive configurations, such as continuous lines of glue, may be used. Also, with the exception of a rewettable adhesive applied along a return envelope flap, the adhesive is applied, preferably in spots, to the continuous web in areas of the panels which will form end tear strips for the outgoing mailer in final assembly. Thus, as used herein, the germ glue "fine" or '°Iines°' embraces both a continuous line of glue or a line of glue spots spaced from one - another:
Further, one or more loose inserts having both persanalized and non-personalized information may be .
inserted into the mailer during its formation as described above. For example, in the first embodiment, loose inserts may be disposed on top of the first panel often the panels are folded about its second foldline. The subsequent foldines and adhesive applications are such as to maintain the inserts within the mailed after final assembly.
To ~n~ure that the return'statement is not damaged or cut by automatic mail opening equipment, fugitive glue lines v or dots of a~hesa:ve ark provi.ded between the panels forming the xetuxn envelope. These are preferably provided adjacent the bottom of the en~relope, and inset from the marginal lines of adhesive forming the side edges of the return envelope: ~y~loc~ting the fugitive glue in this manner, the insert or payment coupon, when located within the return envelope, resides between-the fugitive glue spots on the opposite sides of the envel~pe and hence is spaced from the side maxgin~ of the envelope; which will be cut by the automata.c maa.l opening equipment. This ensures that the envelope mar be opened without damaging or cutting the i insert.
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. , , 'W~ 95/019I'7 . . . : . : , ~PCThIJS9~/C7529 zn a preferred embodiment according to the present invention, there is provided a mailer comprising a single ~ ;
ply having longitudinally and transversely extending edges, first, second, third, fourth, fifth and sixth panels, and first, second, third, fourth and fifth foldlines transversely spaced one from the other and extending ir~ a longitudinal direction, a paa.r of marginal lines of perforations extending transversely along the ply generally parallel to the transversely extending edges and inset therefrom, resp~ctl~rely, defin~.ng marginal tear strips for the mailer i.n the first, second, fifth and sixth panels and at least one of the third and fourth panels, the first and second panels being folded about the first foldline to register the first and second panes with one another and the marginal tear ~t~ips thereof with one another, adhesive along,the rPgistexing marginal tear strips of the ffirst and second panels to secure the registering marginal tear strips to one anather, and adhesive along portions of the first and second panels inset from t3~.e marginal lines of perforations to secure the first, and second panels to one another, respectively; to form a return envelope. The third, ffirst and second. panels are folded about the second foldline such thag the third panel registers with the fourth panel and the first and second panes register with the fifth panel, the marginal tear strips of the second and fifth panels lying in opposition to one another and the third and fourth foldlines .
lying in registry with one another, adhesive along the registering marginal tear strips of the fifth and second panels to.secure the fifth and second panels to. one another, theregisterzng third and fourth panels being folded about registering third and fourth foldlines to register with the registering first; second and fifth panels, adhesive along the marginal. tear strips of the first panel and the one of the third and fourth panels to secure the first panel and the one panel to one another, the sixth panel being folded about the fifth foldline to overlie the fourth panel and ., .....-' . _: : ~ ~.°,~:,...: , ~'~., -.. '; ,.'. -; _..,' '.;,.,. -.
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y adhesive between the sixth and fourth panels to secure the sixth and fourth panels to one another.
In a further preferred embodiment according to the present invention, there is provided a method for producing a mailer formed of a single ply having longitudinally and transversely extending edges, first, second, third,'fourth, fifth and sixth panels; and first, second, third, fourth and fifth. foldli:ne~ transversely spaced one from the other and extending in a longitudinal direction, comprising the steps ' of providing a single ply of web material, imaging information on at least one side of the web, applying first and second tran~~re~se adhesive lines along transversely y extending marginal areas of the first and second panels, the first adhosive line being inset from the second adhesive line; f~lding the first and second panels of the web into overlyz.ng relationship with one another, with the first and second adhesive lines adhering the first and second panels to one another and said first Tines of adhesive. adhering said (first and second panels to one another to form a return i envelope, subsequently applying transverse adhesive lines along marginal areas of one of the second and fifth panels, respectively, folding the first and second panels and the fifth panel into'owerlying relationship with one another, and folding the third panel and the fourth panel about the ~h.ird foldline into overlying relationship with one another whereby the adhesive lines applied to one of the second and ~Figth panels''adhere'the second and fifth panels to ono an,obher, subsequently applying transverse adhesive lines along marginal areas t~f one of the first panel and the fourth panel; folding the thi=d and fourth panels into an ov2rlyir__g relationship with the first, second and fifth panels whereby the adhesive ~.ines applied along one of the first ahd fourth panels adhere the first and fourth panels to one another, subsequently applying adhesive lines to marginal areas of one of the fourth and sixth panels, f ~'~;.~. . . ~..:' ' ' , ~~,..'. ' ~ . . . . . ~ ~ :.~ . .:. 1 ~. ' . ~ , ., . . , .;:;. . ;..
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~'O 9S/01917 , ~ , ... ,; ~~; ', ,., . PCT/US94/07529 a folding the sixth panel and the first through fifth panels into overlying relationship with one another so that the sixth anel is in p juxtaposition with the fourth panel whereby the adhesive lines applied to one of said fourth and .
sixth panels adheres said fourth and fifth panels to one ane~th~r to form a jingle-part statement, and severing each of the single-part statements from the web of material.
In a further pr~~erred embodiment according ~o the present invention, there is provided a mailer comprising a single ply having longitudinally and transversely extending edges, first, second, third, fourth, fifth and sixth panels, ~.nd first, second, third, fourth and fifth foldlines transversely spiced one from the other and extending in a longitudinal direction, a pair of marginal lines of perforations extending transversely along the ply generally parallel ~o the trahsversely extending edges and inset therefrom.; respectively; defining marginal tear strigs for the mailer in the fourth; fifth and sixth panels, the first and sec~n.d panels being folded about the ffirst foldlfine to x'egister the first and second panels with one another with the transversely extending marginal edges thereof in transverse alignment with or inset'from the marginal lines of perfarat~.ons; adhesive portiox~s along the first and second p~ne~:s inset from the marginal edges thereof to secure the first and second panels to one another, resp~eCti:vely, to farm a return envelope, the f~.rst and second panels being folded about the second foldline such that the third panel arid the first and second panels register w'itYa one another, the registering first, second and third panels being folded about the third foldline to register with the fourth panel, the registering first, second, third and fourth panels being folded about the fourth foldline to register with the fifth panel, adhesive along the marginal tear strips of one of the fourth and ... . . :.,.., ,,. . , ,: ,.;_.::.. :. ~ : ,:.. ..,. . .:.;-.
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fifth panels to secure the fourth panel and the fifth panel "

to one another, with the first, second and third panels ~i within the four'ch and fifth panels with transverse marginal edges thereof in transverse alignment with or inset from the marginal lines of perfors.tions; the fourth and sixth panels being folded about the fifth foldline to register with one another and adhesive between the sixth and fourth panels to y~ secure the sixth and fourth panels to one another.

zn a still further preferred embodiment according to the present invention, there ~s provided a method for a producing a mailer formed of a single ply having 1 .
longitudinally and transversely extending edges, first, second, third, fourth, fifth and sixth panels, and first, second; third, fourth and fifth foldlines transversely spaced one from the other and extending in a longitudinal direction,, compzis~.ng the steps of providing a single ply of web material', ~:maging information on at least one side of s the web, forming transversely extends ng edges along the fixst, second and third gavels inset from the transversely v' extending edges-of the fourth; fifth and sixth panels, agapl:~ri.ng transverse adhesive l~.nes along transversely extending marginal areas of th.e first and second panels of the web; foldingthe fixst and second panels of the web about a 'fi.rst foldla:ne into registration with one another, ' with th.e transverse adhesive lines adhering the first and a second panels to one another to form a return envelope, ~'o~ing a r'eturi~ envelope flap in the third panel, folding the f~:rst and second panels and the third panel of the web into registration with onesanother about a second foldline between the flap and the first panel, folding the first, second. and third, panels into registration with the fourth panel about a third foldline, subsequently applying j transverse adhesive lines to one of the fourth and fifth panels along marginal areas thereof, folding the registering first, second, third and fourth panels about a fourth :j .

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~'~ 95/0.917 ~;:; 4 ~ . ~'CTlUS94107529 ~~~2~~2 foldline into registration with the fifth panel with the adhesive securing the fourth and fifth panels to one another, subser~uently applying transverse adhesive lines to marginal areas of one of the sixth and fourth panels of the web, folding the sixth panel and the first through fifth panels into registration with one, another so that the sixth panel is in juxtaposition with the fourth panel whereby the adhesive lines applied to one of the fourth and sixth panels adheres the fourth and fifth panels to one another to form a - single-part statement and after adhering the fourth and fifth panels to one another, severing each of the single-part statements from the web of material.
Accordingly; it is a primary object of the present .

invention to provide a novel and improved single-part statement in the form of a mailer and formed of a single ply having an outgoing mailing envelope, a return business envelope; a statement and a payment coupon, all forming part of the single ply, together with, nove~l~and improved insert, e.g., payment coupon and remittance, locating glue spots along th.e return envelope to preclude damage to, or cutting of, the insert.

81~,T~F I)ES~RIPT~Ol~ C)F fiRE DRAIr~II~TGS i FTGURE 1 is a plan view of a portion of a web #

illustrating a single-part statement mailer and portions of adjoining mailers as part of the web, with foldlines and lines of perforation superposed onto the web to illustrate their respective locations, all in accordaaxce with the present invention;

FIGURE 2 is a view similar to Figure 1 illustrating a j first application of adhesive to the web;

FIGURE 3 is a perspective view of the web being folded ,y i :7 ~~ 9~fa~9~~ 2 ~. 4 r 7 3 2 PCT/US94f0'7529 ~~, ....: a' .~ i s , .... ii ~..
:.., ~~ i about a first foldline to form a return envelope for each '' mailer in the web;

FIGURE 4 is a view similar to Figure 1, with the return envelo~?e farmed and additional adhesive lines applied to the web;

FxGURE 5 is a view of the web of Figure 4, with the panels folded about a seconel foldline;

FIGURE f is a view imi.lar to Figure 5 illustrating the j pane7.s folded about registering third and fourth foldlines and with additional adhesive lines applied subsequent ' 'thereto;

FIGURE 7 is a perspective view of the sixth panel being , folded about the fifth foldl,ine and into registration with the regx.stermg f~.rst through fifth panels, FIGURE 8 i~.lust~ates the web being severed along tramsveree ~u.tliries to form the discrete mailers hereof;

FIGURE 9 is a front elwational view of the return envelope;; with t~.e outer dashed lines illustrating potential cutli.nes for automat~.c snail openers and the interior dashed 'lines illustrating the insert c~ithin the return envelope;

I~ FIGURE '10 illustrates a return envelope cut by an automatic. mail opener with the envelope sidesseparated, exposing the insert for removal;

FIGURE 1.1 is an:enlarged schematic cross-sectional view taken along a line 1.1-lZ i:n Figure 8 and extending in the direction of web travel illustrating the various adhesive attachments between the tear strips of the various panels;

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r; , 13'~ ~~1~I917 . _'.: ~r '; .,; .~' P~T/(1S94/07~29 2142'~~2 FIGURE 12 is a diagrammatic illustration of a method of ~~ ' forming the mailer hereof ;
FIGURE 13 is a view similar to Figure 1 illustrating a further embodiment of a single-part statement mailer according to the present invention;
FIGURE 14 is a perspective view of the embodiment of Figure ~:3 illustrating the return envelope fully formed, with the tear strips removed, and being folded over onto the - next-adjacent panel;
.,., FIGURE 15 is a view similar Figure 14 illustrating to a ~

further folding of the web;
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FTGURE 15 is a view similar Figure 15 illustrating to the application a~ additional glue spots and the registering panel s being folded over a further foldline; and FTGURE I7 is a perspective vie w illustrating the final application of glue and folding of the mailer to forth the complete mailer of th,e embodiment f Figure 13 hereof .
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Reference will now be made in detail to a present preferred,embodirnent of the invention, an example of which ,- i~~allustrated in the accompanying drawings.
3 Referring now to the drawings, particularly to Figure there is illustrated a single-ply Paper web, designated ! W, for movement in a longitudinal direction indicated by the E arrows in Figure 1.. Single-part statement mailers M ar.e i formed continuously from web W. As seen in Figure 1, each mailer, prior to. folding and gluing, comprises a single laid-out flat sheet which includes transversely and . ':.'..' ~. ... . ,~::.;;..~.:~~i ': ,.~:... ,, ~.. ~: y. . , ~:.::.... ,~ ~'.'.' : . ~,.., ;; , , _, .- , .., .
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longitudinally extending edges 3 and 5, respectively, ' relative to the direction of web travel. Edges 3 extend in i the transverse direction a distance greater than longitudinal edges S extend in the longitudinal direction.
In final assembly, each mailer is die-cut, printed, folded, glued; perforated and severed along cutlines C.L. to form discrete mailers. Tt will be appreciated in Figure 1 that the dashed lines extending in the transverse direction illustrate various perforation lines applied to the mailer, as will become clear; subsequent' to its folding about foldlines illustrated by the dot-dashed lines extending in the longitudinal direction, i.e., the direction of web travel. The longitudinally extending dashed lines represent lines o~ perforations formed in the web prior to any fo~:ding .
The web W comprises a continuous single ply of paper from which is formed a plurality of mailers M, a portion of an adjacent leading mailer M1 in they directa.on of web travel and'a portion of a trailing mailer M2 in the direction opposite the direction of web travel being illustrated in Figure ~.: Each mailer is divided into a plurality of panels. For dlarity of the following description of this first embodiment; the first, second, third, fourth, fifth, sixth and se~ren~h panels are designated 11; 12, 13, 14, 15, z~ and 17; respectively. When the mailer is completed as illustrated in Figure 8, the single ply forming mailer M
w~l'1 be f ol.ded about first , second, third, f ourth, f if th and sixth foldlines which; for clarity of the following .
description, are designated 2l, 22, 23, 24, 25 and 26, _;
~ospectively. As will be appreciated from the following , description, the panels; either singly or in combination, form portions of a return envelope, a forwarding mailing envelope, a statecnen;t and a return payment coupon.
Also, the mailer has preprinted information on one or °T

..s;T 1j ..~..~, ~- .~ ' '~~ 95/01917 ~ ~ ~. ~~ P~TIITS94!07529 both sides and on one or more of the panels. The preprinted information can be information of a non-personalized general l or generic nature applicable to all recipients of the !mailer, as well as intelligent or personalized information ,', which may be computer-generated and contain information specific to a particular addressee. For example, the r~ present single-part statement may be used as a bank credit card statement. In that preferred form, the return envelope, which comprises panels 11 and 12 in mailer M, may il have information common to the entire mailing by the issuer of the credit card statement. Thus, the return address of s the sender, as well as other information informing the user how to use the envelope, as well as postal barcode areas, stamp areas, and return address areas may be preprinted on y and common of panels 11 and 12. The account statement itself, which may comprise combined areas of panels 14, 15 and 16, as well as a portion of panel 13, may have both non-persor~alized and personalized intelligent computer-generated inforzvation. For example, the non-personalized information may include standard identifiers for the personalized intelligent information; such as an account number, payment j dtae date, total credit line, cash advance limit, new balance, available credit line, available cash limit, sales ' date~t posting d~.te, reference number, activity since last statement, amount, aceount summaries and other items which would be common to all account statements, .Additionally, these account statement areas of panels 14, 15 and 16 and 13 may~al~o include personalized intelligent information specific to that account, for example, the actual posting date, the identity of the retailer through which the charge was incurred, the actual amount, the actual interest amount, finance charges, charges to date and other information specific to that account. Preferably, such intelligent information is printed an the side of the single ply which will be sealed within the mailer, ensuring the privacy of the information, i.e., the side of the ply facing upwardly ~' . : .. ::: .. ,:.,.: . - ,, ,, .;,., ., . ,. :v-~ ~.. :, . ; . , :. .
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in Figure 1. Additionally, a portion of the panels, for example, panel 14, may comprise marketing or advertising materials and this'likewise can be either non-personalized ~; generic information for all addressees or personalized intelligent information based on computerized information con.cerxia.ng the~ specifis addressee . i . a . , the account holder.
Further; a payment coupon may also form part of the mailer M. Thus, for example, the inset portion of panel 13 may ;:;
comprise a payment coupon having both non-personalized generic arid personalized intelligent infcrmation on the coupon: Such generic information might include a change of address information block or a block labelled amount due.
Other types of non-personal~.zed information which canebe printed on oz~e or both sides of the single ply and in the ~
various panels will readily-be apparent to those skilled in the art, particularly by reference to current standard ' account statements, payment coupons and return envelopes.
The specific personalized intelligent information may include, for example, the account-balance, minimum payment clue; and due date for that particular month and statement and this likewise will be apparent to those of skill in that art:
' The: opposite side of the mailer M from that illustrated ;

in Figure 1, may likewise contain both non-personalized generic and personalized in~.elligent information. For j example; the name and address of the recipient of the mailer ' niay be printed on the back side of panel 15 which forms the mailing address of the outgoing mailer upon ffinal assembly.

Mailer opening informat-ion mtay be disposed on the back side of any one or'rnore of the panels. For those back panels which will be wholly' enclosed within the mailer when .

forwarded, the terms and c~nditions of the account statement may be preprinted, Likewise, on the back side of the paymenb coupon panel ~.3, various information may be requested from the particular recipient, for example, in the ~ ,.,'~~. .; ~- ._ , ., -,. ., , . . .' - . : : . .. w . ~ , . _ , . . ,. ~ ..
. : ". :: . . : ; .., .. . . .-. , . . . . . .
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f~i 5 ,.i.,.:.,."~ ':,;,,..'', v '. , v; ";.~.": , ~':..~ ,.....' ,v.~.. :' .'.,. '~.-.".r. ~ "-.,.. "... ...I~.. . '. ....,;
~~..u".' ... "" :...:''.: ,.. . . .. ~.:"..., .....,. .' ' . .. ...' . . '.. :
.. ..:,..' ' ' .. . . , . . ,. :. .... :. .. . '.. .,. ' .", .., l CVO 95/01917 PCT/IJS9d/07529 i = ".'~. 7 event there is a disputed item on the account statement.
Turning now to the actual formation of the mailer M in the web W and with reference to Figure 1, the web is first longitudinally perforated at transversely spaced locations as needed for the particular statement mailer. Thus, lines of perf oration are f armed U~t 6 and g in Figure 1 to def ine the payment coupon portion of panel 13 and at 9 to define a tear-off line for the return envelope bang-tail panel 17.
The lines of perforations may be formed in the web and the web rewound in coil form for later use. Conversely, the lines of perforations may be provided as the web is removed from the coil Stock prior to printing. The web is then printed with both the non-personalized generic and personalized intelligent information on one or both sides and in the various portions of the mailer panels, as illustrated by the various printing machines 30, 32 and 34 in Figure l2. This imaging or printing may be accomplished by MIDAX print engines 30 and 32, as~described in U.S.
Patent No. 5;132,713, and by a Triton print station 34. The Triton print station 34 mar comprise a Triton UltraJet~' Printer;. a product of Trident, Inc. of Brookfield, Connect~.cut, identified as the Horizontal Headboard. This printer zs a lightweight prinber for specialized printing.
It will be appreciated that the web W is taken from reel 36 and passed through the print machines to complete the printing process.
As illustrated in Figure 12, the printed web is then turned 90° and advanced to a hot glue station 46 (Figure 12) where hot glue or adhesive 48 is applied to the return envelope flap 46 which forms part of panel 11 directly adjacent foldline 23. The hot glue thus forms a rewettable adhesive for the closuxe flap of the return envelope. After , the glue for the return envelope flap is applied, the web is advanced through a die-cut unit 37 where various die cuts .,. . .,,".. .: . , ,.::, : , ;.. . . .. . .,..; , ,, . " . ~ . . . ..,... . -i. .. ..: . .:.- . ,. :: .. ,.: .. . : .. ; . . ., , ; v : . . . , .,.., , .
,~. . . : ~:: :~ :: ~ _ v a ~ ,, : ..: .:, : . .. -._ . , . . . . . . . , 'VV~ ~ISIQ~.917 PCTI1JS94I0'7529 ''- ~-' '.;..
~...:,;v.. , .:: ' r are formed in the web. For example, and referring to Figure ,;' , .a ~., a die-cut window 38 for the return mailer is formed at station 37 in panel ll. Further, a portion of panel 13 is 6 dze cut to form ~.ransversely extending edges 40 inset from transverse cutlin.es C.Lo, as well as inset from transversely extending perforation lines 42 later formed in the mailer "'' after fole3ing and gluing, as will become apparent from the ensuing description: Also, panel 17 is die cut to form a edges 44 inset from the corresponding lines of perforations rt'i ;. 42. The die cutting about the bang-tail panel I7 and the , remittance coupon portion of panel 13 cuts those portions of ~r~ the mailer to an appropriate size so that neither the bang-tail nor the coupon have to be folded to be inserted into the return enve2ope. As will be appreciated, the'lines of erforations form with the outlines C.L. tear strips T.S. in p the transverse marr~ins of the completed mailer. For identificati~an herein, the tear strips are labelled T.S.

.preceded by the number of the panel of which the tear strips are a part: It wi.ll,al~o be a~preci~.ted that the panel 17, when di'e cut to form inset edges 44, forms a bang-tail panel which is provided in the preferred form the mailer. The bang-tail panel; h.o~ve~rer, is not necessary to the mailer and the-mai~,er may be provided without such panel.

~: After die-cut station 37, the web is ad~ranced and a ' cold glue is applied to the web, at a subsequent cold glue station 50 by glue nozzles; to those portions of ~.he panels which will be inunediately subsequently folded and adhered to one another. Thus, at cold glue station 50 (Figure 12), cold glue 4'7 is applied in the regions of the marginal tear strips 1:2T . S . of ~ane~. ~2 on both sides of subsedu.ently formed outlines C.L.' Particularly; and referring to Figure s applied to areas between subsequently the cold glue i .
, applied perforation lines 42 such that the cold glue lies along adjoining tear strips of adjoining mailers in the direction of web gavel. A cold glue line 51 is ~
sx~~; . ., ~:v;. ' ~~.~ . :; -... ;'. ,:, . ::. .;., . .. '':., , ~:. ~ .
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additionally applied at 51 just inside the perforation lines 42 to seal the opposite end edges of panels 11 and 12 to one another when subsequently folded to form the return envelope. Fugitive glue spots 52 are also disposed on -panels Z.1 and l2 inwardly of_ glue lines 51 and on opposite sides of foldline 21: The fugitive glue spots 52 extend along the edges of the return envelope from the foldlir_e 21 a limited distance, for example, less than half the height of the return envelope. As used herein, the term "glue line" and !eglue spots" are used interchangeably, it being appreciated that a continuous line of glue and spaced spots of glue may be used in the glue applications in the present invention. The terms "adhesive" and "glue" are also used ~,n.terck~anc~eably .
Subsequent to application of cold adhesive lines 47, 51 and 5~, the web a.s plow-folded at plow-folding station 54 to fold panels l2'and l2 about foldline 21 to register panels 11 and 12 one with the other and they marginal tear strips 11T . S . and 12T . S'. oa~e with the 'other . Thus , the marginal tear strips of panels 11 and 12 are adhered to one another, the margins of the return envelope inside of lines of :perforations 42 are adhered to one another, and interior portions of the return envelope edges adhere to one another along fugitive g~:ue lines 52. These adhered fugitive glue lines form an insir3e guide for receiving an insert, e.g., a payment coupon and a remittance, whereby the insert is spiced from the' ex~d edges of the return envelope. .When panels 11 and 1.2 are plow-folded, the panel 17~, if used, is also folded about foldline 26 in a reverse direction to overlie the back face-of panel 12 as illustrated in Figure Turning to Figure 4; web W, with the return envelope formed, is then passed through a second cold glue station 58 (Figure 12) where additional cold glue lines 59 are applied ~14~Z~32 ~VIJ 95/01917, P~TlUS9~1/U7529 ,_ ., .." , , ., -.-., v , . - , . r ~:

to the tear strips 12T.S. forming part of panel 12 and a ;, portion of the tear strip 11T.S. of panel 11. Web W is advanced to a furthex plow-fold station 60 where the panels 13, 11~ and 12 are folded about foldline 22 such that panel ~.3 Iies in registration with panel 14 and registering panels 11 and 12 register with panel 15, as illustrated in Figure 5. ConsequentJ:y; the tear strips 15T.S. of panel 15 adhere i to the tear strips 12T.S. of;panel 12 and the portion of the tear strips 11T.S. of panel ll to which glue was applied.
( - With the web folded about foldline 22 as illustrated in Figure 5 and pxior to the next adhesive application, one or ,. more inserts may be disposed within the mailer in loose fashion such that when the recipient opens the mailer, the inserts-f~11 out or can be individually removed. To accoznpl:i~h this; an intelligent inserter 62 (Figure 12) is prov~.ded: lnserter 62 cooperates with the web line to provide one or more ~.nserts S3 (Figure 11) on the web as the web passes the discharge end of the inserter (sixteen insert stations being illustrated for inserting sixteen different types of inserts?. The inserts may contain persona2ized intelligent information preprogrammed in conaunction with the printers 30, 32 and 34 such that designated inserts may be prova:ded mailers addressed to certain. addressees based on 'computez~generated information, e.g., demograghic information: O~ caurse, noz~-personalized inserts may also be inserted in,~o the mailers as they are formed. The inserts, 'when etiiplo~red in the mailer, are located on top of the mailing address side of the return envelope, i.a., on top o~ panel 1.1;
With or without one or more inserts, web W advances to a third cold glue station 70. A~ station 70, cold glue lines 73 are applied to the portions of tear strips 14T.S.
of paned ~.4 exposed by the inset edges 40 of panel 13. Glue lines 73 also extend along overlying tear strip portions 74 of panel 13. When the registering panels 13 and 14 are folded at fold station 80 (Figure 12) about registering foldlines 23 and 24 into registration with registered panels 11, 13 and 15, as well as the bang-tail panel 17 when used, the adhesive line 73 secures tear strip portions 74.of panel 13 along the tear strip 11T.S., as well as the portions of tear strip 14T.S. of panel 14 to the registering portion of tear strip llT.S. of panel 11 as illustrated in Figure 6.
The web is then advanced to a cold.glue station 82 (Figure 12) where cold glue lines 83 are applied along the tear strips 16T.S. of panel 16. Additionally, cold glue 84 is applied along the longitudinally extending edge 5 of panel 16. The web is then advanced to a folding station 88 where panel 16 and panels 11, 12, 13, 14 and 15~ as well as panel 17 if a bang-tail panel is used, are folded into registry with one another. The glue seals the mailer along the tear strip margins.
The web is then advanced to a perforation station 90 (Figure 12) where the perforation lines 42 are applied along the opposite margins of the mailer inset from transverse edges 3 and through the multiple panels. The web is then passed through a cutoff unit 92 where the mailers are cut from the web along cutlines C.L. to forth discrete mailers M.
As illustrated in Figure 8, the web with the discrete mailers folded and glued advance in the direction of web travel, i.e., in the direction of the arrow in Figure 8.
The slitters slit the web along cutlines C.L., bisecting the transversely extending lines of perforations 42, forming the mailer M. Note in Figure 8 that the mailer M has marginal tear strips T.S. along its opposite ends defined by the lines of perforations 42.
To facilitate a further understanding of the mailer of the present invention, reference is made to Figure 11, which VVO 95/0197:
PC~.'/LJS94/07529 I , ~. . V

is a schematic view through a mailer looking along the lines 11-11 in Figure 8. The juxtaposed panels are illustrated in the order of their appearance in the mailer and the glue lines between the tear strips of the mailer are illustrated.
Additi:or,.ally, the bang-ta~.l panel Z7 is disposed between panels l2 and l5 ~x~d the inserts 63 are illustrated by the dsahed lines disposed between panels ll and 13. Note that the ~lu~ l~.nes extend between the tear strips of panels 11 and 14 whereby the inserts are prevented from slipping from the mailer through the opposite ends of the mailer. In Figure I1, the panel ~:3 i.s illustrated with its end edges 40 inset from the lines of perforations 42. The margin 74 in the background portion of the panel 13 is not illustrated.
When a recipient receives the mailer, both marginal tear strips T.S: comprised of strsps 11T>S., 12T.S., 13T.S., ~:4T:S., 15T.5. and 16T.S. at the opposite ends of the mailer may be removed along the Tines of perforations 42. In removing those tear'strips, ~t will bye appreciated that the imailer can be unfolded to a single~p~y form with panels 11 and 12 remaining secured to one another by the glue Tines 51 and fugiti,ve'glue lines 52 to form the return envelope. The account statement information; fox example, may b~ read by the' ~reeipient, from panels 1.6, 15 and 14, and the payment cQUpon in panel 13. I~ all i in order, the recipient may remove the account statement from the payment~coupon portion of the panel 13 by detaching the account statement along longi:tudinal.~y extending line of perforations 8.
Additionally; the coupon statement itself may be detached .from he return envelope flap along line of perforations 6.
The payment cQUpon, because its edges 40 are inset, may be inserted into the return envelope, together with a remittance, and wathin the fugitive glue lines 51. The return flap is then moistened; folded over a foldline and sealed to the outer face of gavel L2. If the bang-tail panel 17 forms part of the mailer, it is removed before the s..w..~. .~.__.. ; . .:, _... , ; ..,:, ; , ,, ~ ..:. . , , m:
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return envelope is sealed by tearing along the line of perforations 9.
When the return envelope is received by the payee, automatic openers may be used to remove margins of the v;
return envelope. For example, automatic slitters may slit off an eighth to a c~ua~ter inch of the top margin, as well :' as end m~.rgins of the return envelope, to enable suction devices to pull the panels apart, exposing the contents of the return envelope far extraction. It will be appreciated that the content , including the payment coupon and payment, Jti la.e within the fugitive glue lines and thus are out of the way of the automatic mail opening cutters whereby the payment coupon and payment are free of damage and mutilation.
Referring now to the embodiments hereof illustrated in Figures l3~-17, wherein like reference numerals are applied to like'part,s, followed by the suffix "a", there is illustrated a mailer l~Ia formed of six panels lla, 12a, 13a, '14a, 15a and 16aA seventh panel 17a is also included when r a bang-tail is provided the return envelope. As illustrated in Figui°e 13; adjacent mailers are shown in the web Wa, with eaeh mailer being defined by transverse and longitudinally extending edges ~a'and 5a. Web Wa is printed as previously described with respect to the printers 30, 32 and 34 and is also gassed through the die-cut station 37 and the following hot~glue station 46; where the rewettable adhesive is applied to the-return exw~lope flap. .
'' 2n this embodiment; howe~rer, the foldlines, sequence of glua,ng and the folding of the panels is different than in the prior embodiment, with the exception of foldlines 21a and 26a: Thus; the return envelope comprised of panels lla ? and 12a is formed similarly as in the previous embodiment, but with glue lines applied to one of the panels 11a and 12a i only in the areas inset from the lines of perforations 42a such that, upon folding the panels lla and 12a about foldline 21a, panels lla and 12a form a return envelope.
After the return envelope is formed, or before it is folded to forth the return envelope, and as illustrated in .108 at Figure 12, the web is passed through a cut-off station 108 where the marginal portions of panels lla and 12a, which would otherwise form the tear strips as in the previous embodiment, are cut from the web. Consequently, the marginal edges of the return envelope formed in the web Wa are aligned with or slightly inset from the lines of perforations 42a.
With the return envelope thus formed, it will be seen that panel 17a overlies panel 13a and foldlines 9a and 101 register one with the other. In that configuration, the web Wa is advanced to a second folding station where the return envelope is folded about the registering foldlines 9a and 101 to register panels lia, 12a and 17a with panel 13a.
Note that the foldline 21a registers with the foldline 102 and that none of the edges of panels 11a, 12a, l7a and 13a lie outside the lines of perforations 42a. The web Wa is then advanced to a third folding station where the registering panels 13a, 17a, lla and 12a are folded about foldline 102 and registered with panel 14a. The web is then advanced to a gluing station where glue is applied to the margins of one of panels 14a and 15a. Upon advancement of the web through a subsequent folding station, the registering panels 14a, lla, 12a, 17a and 13a are registered with panel 15a, with the glue lines in the marginal tear strips adhering panels 14a and 15a to one another, thus sealing off the opposite inset ends of panels lla, 12a, 17a and 13a. Web Wa is subsequently advanced to a final glue station where glue is applied to the tear strips of one of panels 16a and 14a, glue being applied to panel 16a as illustrated in Figure 17. A subsequent folding station registers panel 16a with the registered panels 14a, lla; 12a, 17a, 13a and 15a. It will be appreciated that inserts, similarly as in the prior embodiment, may be received in web Wa at any stage subsequent to the formation of the return envelope and the adhesive securement of the panels 14a and 15a to one another.
It will be appreciated that when the recipient receives a mailer of this type, the tear strips lie only on panels 16a, 14a and 15a, the margins of panels 17a and 13a having been inset by the die-cutting process and the margins of the return envelope formed by panels lla and 12a having been cut to lie along or lie slightly inset from the lines of perforations 42 forming the tear strips in panels 14a, 15a and 16a. In this manner, when the recipient removes the marginal tear strips from the statement, the margins of the return envelope have previously been cleanly cut off in the mailer manufacturing process. Thus. there is ensured a cleanly cut margin on the return envelope which prevents any misalignment in the automatic mail opening machine in the event that the tear-off strips are not torn cleanly from the return envelope. Additionally, the return envelope flap may not be properly folded over the return envelope, causing bubbling or skewing of the flap, leading to misalignment of the slitter blades in the automatic opener. By folding the return envelope initially along a scoreline beneath the rewettable glue flap and above the return envelope pocket, the folding of the return envelope flap about the appropriate foldline by the receipt of the mailer is facilitated, avoiding any skewing or bubbling of the return envelope flap.
While the invention has been described with respect to what is presently regarded as the most practical embodiments thereof, it will be understood by those of ordinary skill in the art that various alterations and modifications may 3~e r . , ..:. .-:_ r ,,::.- , .: :. .. :. : ' r;.-~''~ 951~D191'7 ~ ~ ~ ~ t~., ~ 3 ~ P('TlI1'~9dIO7529 ,~ ~ . . ., .. ,: _.
~t :~4 2 5 made which nevertheless remain within the scope of the '~>~' invention as defined by the claims which follow.
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Claims (22)

WHAT IS CLAIMED IS:

1. A mailer comprising:

a single ply having longitudinally and transversely extending edges; first, second; third, fourth, fifth and sixth panels, and first, second, third, fourth and fifth foldlines transversely spaced one from the other and extending in a longitudinal direction;

a pair of marginal lines of perforations extending transversely along said ply generally, parallel to said transversely extending edges and inset therefrom, respectively, defining marginal tear strips for the mailer in said first; second, fifth and sixth panels and at leapt one of said third and fourth panels;

said first and second panels being folded about said first foldline to register said first and second panels with one another and the marginal tear strips thereof with one another;

adhesive along said registering marginal tear strips of said first and second, panels to secure paid registering marginal tear strips to one another, and adhesive along portions of said first and second panels inset from said marginal lines of perforations to secure said first and second panels to one another,respectively, to form a return envelope ;

said third, first and second panels being folded about said second foldline such that said third panel registers with said fourth panel and said first and second panels register with said fifth panel, the marginal tear strips of said second and fifth panels lying in opposition to one another and said third and fourth foldlines lying in registry with one another;

adhesive along the registering marginal tear strips of said fifth and second panels to secure said fifth and second panels to one another;

said registering third and fourth panels being folded about registering third and fourth foldlines to register with said registering first, second and fifth panels;

adhesive along the marginal tear strips of said first panel and said one of said third and fourth panels to secure said first panel and said one panel to one another;

said sixth panel being folded about said fifth foldline to overlie said fourth panel; and adhesive be ween said sixth and fourth panels to secure said sixth and fourth panels to one another.

2. A mailer according to Claim 1 where an one of said third and fourth panels has transversely extending edges inset from the marginal lines of perforations of next-adjacent panel.

3. A mailer according to Claim 1 wherein said first panel includes a return envelope flap having a longitudinally extending edge thereof adjacent said third foldline and adhesive applied along said return envelope flap.

4, A mailer according to Claim 1 including a seventh panel in said ply adjacent said second panel, a sixth foldline between said second and seventh panels, said seventh panel being folded about said sixth foldline to lie in registration with said second panel and between said second and fifth panels in said mailer.

5. A mailer according to Claim 4 wherein said seventh panel has transversely extending edges inset from the marginal lines of perforation of said second panel.

6. A mailer according to Claim 1 wherein said ply is continuous and said panels lie in said continuous ply from one longitudinally extending edge of said ply to an opposite longitudinally extending edge of said ply in the order from one of said edges of said second, first, third, fourth, fifth and sixth panels.

7. A mailer according to Claim 1 including a seventh panel in said ply adjacent said second panel, a sixth foldline between said second and seventh panels, said seventh panel being folded about said sixth foldline to lie in registration with said second panel and between said second and fifth panels in said mailer, said ply being continuous and said panels lying in said continuous ply from one longitudinally extending edge of said ply to an opposite longitudinally extending edge of said ply in the order from one of said edges of said seventh, second, first, third, fourth, fifth and sixth panels.

8. A mailer according to Claim 1 wherein said third panel has transversely extending edge inset from the marginal lines of perforations of said first and fourth panels, a portion of the inset transversely extending edges of said third panel lying parallel to the transversely extending edges of said first, second, fourth, fifth and sixth panels.

9. A mailer according to Claim 1 wherein one of said third and fourth panels has transversely extending edges inset from the marginal lines of perforations of next-adjacent panels, said first panel including a return envelope flap having a longitudinally extending edge thereof adjacent said third foldline and adhesive applied along said return envelope flap, said ply being continuous and said panels lying in said continuous ply from one longitudinally extending edge of said ply to an opposite longitudinally extending edge of said ply in the order from one of said edges of said second, first, third, fourth, fifth and sixth panels.

10. A mailer according to Claim 1 wherein one of said third and fourth panels has transversely extending edges inset from the marginal lanes of perforations of next-adjacent panels, said first panel including a return envelope flap having a longitudinally extending edge thereof adjacent said third foldline and adhesive applied along said return envelope flap, and a seventh panel in said ply adjacent said second panel, a sixth foldline between said second and seventh panels, said seventh panel being folded about said sixth foldline to lie in registration with said second panel and between said second and fifth panels in said mailer, said seventh panel having transversely extending edges inset from the marginal lines of perforation of said second panel said ply being continuous and said panels lying in said continuous ply from one longitudinally extending edge of said ply to an opposite longitudinally extending edge of said ply in the order from one of said edges of said seventh, second, first, third, fourth, fifth and sixth panels.

11. A mailer according to Claim 1 including at least one insert within said mailer and between said first and third panels.

12. A mailer comprising:

single ply having longitudinally and transversely extending edges, first, second, third, fourth, fifth and sixth panels, and first, second, third, fourth and fifth foldlines transversely spaced one from the other and extending in a longitudinal direction;
a pair of marginal lines of perforations extending transversely along said ply generally parallel to said transversely extending edges and inset therefrom, respectively, defining marginal dear strips for the mailer in said fourth, fifth and sixth panels;
said first and second panels being folded about said first foldline to register said first and second panels with one another with the transversely extending marginal edges thereof in transverse alignment with or inset from said marginal links of perforations;
adhesive portions along said first end second panels inset from said marginal edges thereof to secure said first and second panels to one another, respectively, to form a return envelope;
said first and second panels being folded about said second foldline such that said third panel and said first and second panels register with one another;
said registering first, second and third panels being folded about said third foldline to register with said fourth panel;
said registering first, second, third and fourth panels being folded about said fourth foldline to register with said fifth panel;
adhesive along the marginal tear strips of one of said fourth and fifth panels to secure said fourth panel and said fifth panel to one another, with said first, second and third panels within said fourth and fifth panels with transverse marginal edges thereof in transverse alignment with or inset from said marginal lines of perforations;
said fourth and sixth panels being folded about said fifth foldline to register with one another; and adhesive between said sixth and fourth panels to secure said sixth and fourth panels to one another.

13. A mailer according to Claim 12 wherein said third panel includes a return envelope flap, said second foldline extending between said flap and said first panel.

14. A mailer according to Claim 12 including a seventh panel in said ply adjacent said second panel, a sixth foldline between said second and seventh panels, said seventh panel being folded about said sixth foldline to lie in registration with said third panel and between said third and second panels in said, mailer.

15. A mailer according to Claim 12 wherein said ply is continuous and said panels lie in said continuous ply from one longitudinally extending edge of said ply to an opposite longitudinally extending edge of said ply in the order from one of said edges of said second, first, third, fourth, fifth and sixth panels.

16. A mailer according to Claim 12 including at least one insert within said mailer and between said fourth and fifth panels.

17. A method for producing a mailer formed of a single ply having longitudinally and transversely extending edges, first, second, third, fourth, fifth and sixth panels, and first, second, third, fourth and fifth foldlines transversely spaced one from the other and extending in a longitudinal direction, comprising the steps of:
providing a single ply of web material;
imaging information on at least one side of said web;
applying first and second transverse adhesive lines along transversely extending marginal areas of one of said first and second panels, said first adhesive line being inset from said second adhesive line;
folding said first and second panels of said web into registration with one another, with said first and second transverse adhesive lines adhering said first and second panels to one another and said first lines of adhesive adhering said first and second panels to one another to form a return envelope;
subsequently applying transverse adhesive lines along marginal areas of one of said second and fifth panels;
respectively;
folding said first and second panels and said fifth panel into, registration with one another, and folding said third panel and said fourth panel about said third foldline into registration with one another whereby the adhesive lines applied to one of said second and fifth panels adhere said second and fifth panels to one another;
subsequently applying transverse adhesive lines along marginal areas of one of said first and fourth panels;
folding said third and fourth panels into registration with said first, second and fifth panels whereby the adhesive lines applied along one of said first and fourth panels adhere said first and fourth panels to one another;
subsequently applying adhesive lines to marginal areas of one of said fourth and sixth panels;~~
folding said sixth panel and said first through fifth panels into registration with one another so that said sixth panel is in juxtaposition with said fourth panel whereby the adhesive lines applied to one of said fourth and sixth panels adheres said fourth and fifth panels to one another to form a single-part statement; and~
severing each of said single-part statements from said web of material.

18. A method according to Claim 17 including forming lines of perforations inwardly of the line of adhesive applied to said one of said second and fifth panels, said one of said first and fourth panels, said one of said fourth and sixth panels end outwardly of said first line of adhesive.

19. A method according to Claim 18 including applying adhesive in the longitudinal direction to a portion of one of said first and second panels forming a return envelope flap for said return envelope.

20. A method according to Claim 17 including inserting at least one loose insert into said mailer subsequent to folding said first and second panels.

21. A method according to Claim 17 including die cutting said web to form in at least one of said third and fourth panels transverse edges inset from the transverse edges of said first and second panels forming said return envelope to enable insertion of a die-cut portion of said one of said third and fourth panels into said return envelope without folding.

22. A method for producing a mailer formed of a single ply having longitudinally and transversely extending edges, first, second, third, fourth, fifth and sixth panels, and first, second, third, fourth and fifth foldlines transversely spaced one from the other and extending in a longitudinal direction, comprising the steps of:
providing a single ply of web material;
imaging information on at least one side of said web;
forming transversely extending edges along said first, second and third panels inset from the transversely extending edges of said fourth, fifth and sixth panels;
applying transverse adhesive lines along transversely extending marginal areas of said first and second panels of said web;
folding said first and second panels of said web about a first foldline into registration with one another, with said transverse adhesive lines adhering said first and second panels to one another to form a return envelope;
forming a return envelope flap in said third panel;
folding said first and second panels and said third panel of said web into registration with one another about a second foldline between said flap and said first panel;
folding said first, second and third panels into registration with said fourth panel about a third foldline;
subsequently applying transverse adhesive lines to one of said fourth and fifth panels along marginal areas thereof;
folding said registering first, second, third and fourth panels about a fourth foldline into registration with said fifth panel with said adhesive securing said fourth and fifth panels to one another;
subsequently applying transverse adhesive lines to marginal areas of one of said sixth and fourth panels of said web;
folding said sixth panel and said first through fifth panels into registration with one another so that said sixth panel is in juxtaposition with said fourth panel whereby the adhesive lanes applied to one of said fourth and sixth panels adheres said fourth and fifth panels to one another to form a single-part statement; and after adhering said fourth and fifth panels to one another, severing each of said single-part statements from said web of material.