Method of sealing business communication documents using segmented cohesive patterns having separable inserts

Abstract

The present invention is directed to a method of using a sealing nip configuration to produce a sealed business communication having at least one insert. The sealing nip is constructed from a pair of rollers, with at least one roller having a smooth surface and the other roller having a series of circumferentially extending raised areas that are used to apply directed pressure to marginal areas containing a cohesive.

1 . A method for creating a sealed business communication document, comprising the steps of; 
 supplying at least one business form blank, said blank having a thickness, first and second faces, first and second longitudinally extending sides and first and second transversely extending edges, first and second longitudinally extending lines of weakness each of which are spaced inwardly from first said first and second longitudinally extending sides to create first and second longitudinally extending marginal areas and first and second transversely extending lines of weakness each of which are spaced inwardly from said first and second transversely extending edges to form first and second transversely extending marginal areas, each of said first and second longitudinally extending marginal areas and said first and second transversely extending marginal areas having a pattern of cohesive and an insert applied to one of said first and second faces;    providing a sealing nip configuration, said sealing nip configuration consisting of a first roller having a substantially continuous surface and a second roller having at least first and second raised surface areas, each of said surface areas having a width of less than about one quarter of an inch and said first and second raised areas are spaced a distance from one another such that said insert on said one of said first and second faces of said blank can pass between said raised surface areas without contact;    folding said at least one business form blank such that at least a portion of said first and second longitudinally extending marginal areas are in contact with one another to form a folded blank;    inserting said at least one business form blank into said sealing nip configuration; and    sealing said at least said portion of said first and second longitudinally extending marginal areas by contacting said marginal areas with said first and second raised surface areas to form a sealed business communication document.    
   
   
       2 . A method as recited in  claim 1 , including a further step of rotating said folded blank ninety degrees after the step of sealing.  
   
   
       3 . A method as recited in  claim 1 , wherein said second roller is provided with third and fourth raised areas spaced inwardly from said first and second raised areas and having a width of less than one quarter of an inch, said third and fourth raised areas are spaced from one another a distance sufficient from one another to allow an insert to pass between said third and fourth rollers without contact.  
   
   
       4 . A method as recited in  claim 3 , including a further step of inserting said folded blank such that said first and second transversely extending edges are in contact with third and fourth raised areas on said second roller after the step of sealing.  
   
   
       5 . A method as recited in  claim 1 , including a further step of printing on at least one of said first and second faces of said business form blank after the step of supplying said at least one blank.  
   
   
       6 . A method as recited in  claim 1 , wherein said insert has a thickness that is greater than said thickness of said business form blank.  
   
   
       7 . A method as recited in  claim 1 , wherein said insert is a removable magnetic piece.  
   
   
       8 . A method as recited in  claim 1 , wherein said insert is a removable card piece.  
   
   
       9 . A method as recited in  claim 1 , wherein said first and second raised areas have a width of about one thirty second of an inch.  
   
   
       10 . A method of sealing an insert carrying business form, comprising the steps of; 
 supplying a business form blank having first and second faces, said business form blank having a first thickness and first and second longitudinally extending marginal areas, first and second transversely extending areas with each of said areas having a pattern of cohesive;    positioning an insert on one of said first and second faces, said insert having a second thickness that is greater than said first thickness, said insert disposed inwardly of each of said longitudinally extending marginal areas and said first and second transversely extending marginal areas and said insert has a first length and width;    folding said blank so that said patterns of cohesive in each of said marginal areas are in contact with one another to create a folded blank;    inserting said folded blank in to a sealing nip assembly, said sealing nip including a first substantially smooth roller and a second roller having a series of circumferentially extending ridges spaced from one another a distance greater than one of said first length or width of said insert, each of said ridges having a width of less than about one quarter of an inch; and    sealing said folded blank about said marginal areas to form a sealed business communication having said insert.    
   
   
       11 . A method as recited in  claim 10 , including a further step of shifting said folded blank ninety degrees after the step of sealing.  
   
   
       12 . A method as recited in  claim 10 , including a further step of printing on said folded blank after the step of sealing.  
   
   
       13 . A method as recited in  claim 10 , wherein each of said circumferentially extending ridges has a thickness of about one thirty second of an inch.  
   
   
       14 . A method as recited in  claim 10 , wherein said second roller includes third and fourth circumferentially extending raised areas with each of third and fourth rollers having a width of less than one quarter of an inch.  
   
   
       15 . A method as recited in  claim 10 , wherein said first and second circumferentially extending raised areas are spaced from one another a distance of greater than four inches.  
   
   
       16 . A method as recited in  claim 14 , wherein said third and fourth circumferentially extending raised areas are spaced from one another a distance of greater than about two inches.  
   
   
       17 . A method as recited in  claim 14 , wherein said insert has a dimension of about 2⅛ inches by about 3⅜ inches.  
   
   
       18 . A method as recited in  claim 10 , wherein said insert is selected from a group including cards, magnets and tags.  
   
   
       19 . A method of producing a sealed business communication containing an insert, comprising the steps of; 
 providing a business form intermediate having a first thickness, said intermediate having first and second faces and a marginal area extending substantially entirely about a perimeter of said intermediate, said perimeter defined by first and second longitudinally extending sides, first and second transversely extending edges and a line of weakness spaced inwardly of said longitudinally extending sides and transversely extending edges;    placing an insert on said first face of said intermediate and inwardly of said marginal area, said insert having a second thickness that is greater than said first thickness;    printing indicia on said first face of said intermediate and printing substantially simultaneously matching indicia on said insert;    folding said intermediate about said insert such that said cohesive in said marginal areas is in contact with itself to create a folded blank;    placing said folded blank into a sealing nip, said sealing nip having first and second rollers with said second roller having at least first, second, third and fourth circumferentially extending raised areas, with each of said areas having a width of less than one quarter of an inch and each of said areas spaced from one another a distance of greater than one quarter of inch and said third and fourth raised areas positioned inwardly of said first and second raised areas; and    sealing said folded blank by contacting at least first and second raised areas of said second roller to said marginal areas.    
   
   
       20 . A method as recited in  claim 19 , including a further step of shifting said folded blank ninety degrees and reinserting said folded blank into said sealing nip such that said third and fourth raised areas are in contact with a portion of said marginal areas after the step of sealing.