Reusable envelope and method of making same

Abstract

A reusable envelope includes a plurality of panels defining a pocket having an opening for receipt of the content material. The reusable envelope also includes a flap closure having first and second bond lines and first and second flap folds disposed between the bond lines. The first flap fold and first bond line are adapted to close the pocket during an initial mail delivery while the second flap fold and second bond line are adapted to close the pocket for reuse during a subsequent mail delivery. A tear strip is disposed between the front panel and the flap closure to open the pocket for removal of the mailpiece content material. Upon removal of the tear strip and insertion of content material associated with the subsequent mail delivery, the second bond line connects the panels to close the pocket for reuse of the envelope.

1 . A reusable envelope for mailing content material, comprising:
 a plurality of panels defining a pocket having an opening for receipt of internal content material;   a flap closure having first and second bond lines and first and second flap folds disposed between the bond lines, the first flap fold and first bond line adapted to close the pocket during an initial mail delivery and the second flap fold and second bond line adapted to close the pocket for reuse during a subsequent mail delivery; and   a tear strip disposed between, and connecting, the front panel and the flap closure, the tear strip adapted to separate the flap closure from the front panel to open the pocket for removal of the mailpiece content material following the initial mail delivery.   
     
     
         2 . The reusable envelope according to  claim 1  wherein the plurality of panels includes a front panel having a window disposed therein for viewing delivery information printed on the content material, and
 a rear panel connecting to the front panel along a panel fold, the front and rear panels connecting along oppositely-disposed lateral edges to define the pocket for receipt of the mailpiece content material.   
     
     
         3 . The reusable envelope according to  claim 1  wherein the tear strip is defined by, and between, perforation lines which are spaced apart to accept postage indicia therebetween. 
     
     
         4 . The reusable envelope according to  claim 1  wherein the first flap fold is disposed between the second flap fold and the second bond line and wherein the second flap fold is disposed between the first flap fold and the first bond line. 
     
     
         5 . The reusable envelope according to  claim 3  wherein the tear strip is bifurcated into at least two portions by a tab line perforation facilitating removal of the tear strip. 
     
     
         6 . The reusable envelope according to  claim 1  further comprising a sealing tab projecting laterally from each side edge of a panel and connecting thereto along a tab fold, and wherein the tear strip is defined by a pair of perforation lines which are spaced apart, one of the perforation lines crossing each of the tab folds and defining a portion which corresponds in shape to the edge of an adjacent panel to facilitate removal of the tear strip from the panel. 
     
     
         7 . The reusable envelope according to  claim 1  wherein the first bond line of the flap closure adhesively bonds to the rear panel during the initial mail delivery and wherein second bond line of the flap closure adhesively bonds to the front panel during the subsequent mail delivery. 
     
     
         8 . The reusable envelope according to  claim 1  wherein the tear strip is defined by, and between, lines of perforation and further comprising a reinforcing film bonded to a face surface of the tear strip and disposed between the lines of perforation. 
     
     
         9 . The reusable envelope according to  claim 1  wherein the tear strip is defined by, and between, lines of perforation, and further comprising a reinforcing material disposed adjacent to, and outboard of, each line of perforation to mitigate damage to the envelope when removing the tear strip. 
     
     
         10 . The reusable envelope according to  claim 1  wherein the first and second bond lines are substantially parallel and separated by a threshold dimension to facilitate manufacture by automated fabrication equipment. 
     
     
         11 . A method for fabricating a reusable envelope, comprising the step of:
 cutting sheet material into a flat pattern comprising first and second panels connecting along a panel fold, a side tab projecting from and connecting to each side edge of one of the panels along tab folds, a flap closure having first and second fold lines, and a tear strip disposed between and connecting the flap closure to the front panel;   applying adhesive bonding material along the flap closure to define first and second bond lines, the bond lines disposed to each side of a flap fold such that the first and second flap folds are disposed between the first bond and second bond lines;   applying adhesive bonding material to each side edge of the second panel, thereby defining a pair of tab bond lines;   perforating the sheet material between the first panel and the flap closure to define a tear strip therebetween, and   assembling the first and second panels in combination with the side tabs such that the panels are bonded along the tab bond lines, the panels and side tabs defining a pocket for receipt of content material.   
     
     
         12 . The method according to  claim 9  further comprising the step of cutting a window into the first panel for viewing delivery information printed on the content material. 
     
     
         13 . The method according to  claim 9  further comprising the step of bifurcating the tear strip into two portions by a tab line perforation. 
     
     
         14 . The method according to  claim 9  further comprising the step of perforating each of the side tabs along a line corresponding in shape to an edge of an adjacent panel, the tab perforation facilitating removal of the tear strip from the panel. 
     
     
         15 . The method according to  claim 9  wherein the tear strip is defined by, and between, lines of perforation and further comprising the step of structurally augmenting the face surface of the tear strip to mitigate damage to the envelope upon removal of the tear strip. 
     
     
         16 . The reusable envelope according to  claim 1  wherein the tear strip is defined by, and between, lines of perforation, and further comprising the step of reinforcing the envelope in areas adjacent to a line of perforation.