Envelope having improved overlap profile

Abstract

An envelope assembly is provided for improved performance of a mailing envelope in the automated mail handling process. The envelope comprises a front panel having top, bottom and side edges and forming an envelope front surface, side flaps extending front the side edges, a rear panel extending from the bottom edge and combining with the side flaps to form an envelope rear surface, and a closure flap extending from the top edge for securing the envelope in a closed position. The rear panel is sized and configured to have a lesser width than the front panel as to expose the side flaps along the envelope rear surface. In this configuration, an automated mail opening machine must only substantially cut through the side flaps and front panel to open the envelope along the side edges, as opposed to having to also cut through a substantial portion of the rear panel and an adhesive holding the rear panel and side flaps together.

1 . An envelope having a top edge, a bottom edge and first and second side edges, the envelope comprising: 
 a front panel;    a rear panel interconnected with the front panel along the bottom edge ot the envelope, the rear panel having a top edge and first and second side edges, the first and second side edges having a transition region defining an area of panel width that is reduced from the panel width of the rear panel along the bottom edge;    first and second side flaps interconnected with the front panel along a line of weakness to define opposite side edges for the envelope as the first and second side flap are folded toward the rear panel, the first and second side flaps extending inwardly a sufficient span as folded from the line of weakness to extend beyond the first and second side edges of the rear panel, the first and second side flaps being secured to the rear panel to cooperatively form an envelope rear surface positioned opposite of the front panel;    a closure flap interconnected with the front panel along a common top edge; and    at least one side region bounded by one of the first and second side edges of the envelope and a respective edge of the first and second side edges of the rear panel, the at least one side region consisting of a portion of the front panel and one of said first and second side flaps, the at least one side region extending from one of the first and second side edges of the envelope for at least ⅛ of an inch for at least sixty percent of the height of the respective side edge of the rear panel.    
     
     
         2 . The envelope of  claim 1 , wherein the rear panel overlies a portion of the first and second side flaps as folded.  
     
     
         3 . The envelope of  claim 1 , wherein the rear panel underlie the first and second side flaps as folded.  
     
     
         4 . The envelope of  claim 3 , wherein at least one side region comprises a width of at least ¼ of an inch for at least seventy-five percent of the longitudinal dimension from the rear panel bottom edge to the rear panel top edge.  
     
     
         5 . The envelope of  claim 1 , wherein the closure flap has an outer edge forming a set of shoulder areas proximal to the top edge, the shoulder areas having a rounded contour extending for at least ½ of an inch along the outer edge.  
     
     
         6 . The envelope of  claim 1 , wherein the closure flap has an outer edge forming a set of shoulder areas proximal to the top edge, the shoulder areas having a rounded contour extending for at least 1 inch along the outer edge.  
     
     
         7 . The envelope of  claim 5 , wherein the radius of curvature of the shoulder areas is at least one inch.  
     
     
         8 . The envelope of  claim 6 , wherein the radius of curvature of the shoulder areas is about 1⅝ inches.  
     
     
         9 . The envelope of  claim 1 , wherein a top edge of the envelope rear surface forms a throat region sloping downward from an upper point of both the first and second side panel side edges, the throat region having smooth transition points between the rear panel top edge and a first side flap top edge, and between the rear panel top edge and a second side flap top edge.  
     
     
         10 . An envelope comprising: 
 a front panel having a generally rectangular shape and forming an envelope front surface;    a rear panel interconnected with the front panel along a common bottom edge, the rear panel having a top edge and first and second side edges, the first and second side edges having a transition region defining an area of panel width that is reduced from the panel width along the bottom edge;    first and second side flaps interconnected with the front panel along common opposite side edges, the side flaps being fixedly joined to the rear panel to form an envelope rear surface positioned opposite of the envelope front surface; and    a closure flap interconnected with the first panel along a common top edge, the closure flap having an outer edge forming a set of curved shoulder areas proximal to the top edge, the shoulder areas extending for at least one inch along the outer edge and having a radius of curvature of at least one inch;    wherein the rear panel is fixedly joined to the first and second side flaps at least proximal to an inside edge of the side flaps, the side flaps being exposed along the envelope rear surface as to define a first overlap transverse dimension from the rear panel first side edge to the first side flap side edge and a second overlap transverse dimension from the rear panel second side edge to the second side flap side edge, both the first and second overlap transverse dimensions comprising a width of at least ⅛ of an inch for at least sixty percent of the longitudinal dimension from the rear panel bottom edge to the rear panel top edge.