Envelope gusset with wrap-around attachment

Abstract

Envelopes (10) include gussets (33) that extend between front and rear walls (12, 14) of the envelopes. An attachment lip (60) extends from at least one side of the gusset and wraps around an exterior surface of the envelope to form a seam that is displaced from the gusset.

Description

Docket No. 194313.18502ENVELOPE GUSSET WITH WRAP-AROUND ATTACHMENTCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 63 / 569,051, filed March 22, 2024, the contents of which are incorporated by reference herein in their entirety.BACKGROUND

[0002] Envelopes are in widespread use to ship small and medium-sized items in e-commerce and other applications. Some envelopes include gussets connected to the front and rear walls of the envelope. The gussets facilitate movement of the front and rear walls toward and away from each other and thus allow the envelope to accommodate larger items than otherwise would be possible. The gussets typically are attached to one or both of the front and rear walls by seams made up, in part, by the gussets.

[0003] The use of paper to manufacture shipping envelopes is increasing due the ability of paper to be recycled. The seams in the gussets of paper envelopes, however, can be susceptible to tearing and other damage, especially when the gussets are fully expanded due to the presence of a relatively large item within the envelope.SUMMARY

[0004] In one aspect of the disclosed technology, an envelope for holding an item includes a first wall, a second wall overlying the first wall, a first gusset extending from the first wall, and a first attachment lip extending from the first gusset, the first attachment lip overlaying and affixed to an exterior side of the envelope. The first and second walls and the first gusset cooperatively define a pocket located between the first and second walls, the pocket configured and1169405775Docket No. 194313.18502dimensioned to contain the item, and a pocket opening allowing access to the pocket from an exterior of the envelope for loading the item into the pocket.

[0005] In another aspect of the disclosed technology, the first attachment lip is configured to wrap around the second wall as the first attachment lip extends from the first gusset.

[0006] In another aspect of the disclosed technology, the first attachment lip is affixed to an exterior surface of the second wall.

[0007] In another aspect of the disclosed technology, the first gusset is unitary with the first wall and the first attachment lip.

[0008] In another aspect of the disclosed technology, the first attachment lip defines a seam between the first gusset and the second wall.

[0009] In another aspect of the disclosed technology, the first seam is displaced from the first gusset.

[0010] In another aspect of the disclosed technology, the envelope further includes a bonding element sealing the first attachment lip to the exterior side of the envelope.

[0011] In another aspect of the disclosed technology, the bonding element is an adhesive.

[0012] In another aspect of the disclosed technology, the first and second walls and the first gusset are made of paper.

[0013] In another aspect of the disclosed technology, a side of the first gusset extends from the first wall and the first attachment lip extends from a second side of the gusset.

[0014] In another aspect of the disclosed technology, the first gusset includes a first panel extending from the first wall, and a second panel extending from the first panel, and the first attachment lip extends from the second panel.2169405775Docket No. 194313.18502

[0015] In another aspect of the disclosed technology, the first panel is connected the first wall by a first living hinge between the first panel and the first wall, and the second panel is connected the first panel by a second living hinge between the first panel and the second panel.

[0016] In another aspect of the disclosed technology, the first living hinge is configured the move into and out of the envelope pocket as the first wall and the second wall move toward and away from each other.

[0017] In another aspect of the disclosed technology, the first panel and the second panel define a convex bend as the first wall and the second wall move toward each other.

[0018] In another aspect of the disclosed technology, a bottom side of the first wall is affixed to a bottom side of the second wall.

[0019] In another aspect of the disclosed technology, the envelope further includes a flap hingedly connected to the first flexible wall to rotate between an open position, allowing access to the pocket through the pocket opening, and a closed position in which the flap extends from the first flexible wall, across the pocket opening and onto the second flexible wall to attach thereto, thereby closing the pocket opening.

[0020] In another aspect of the disclosed technology, the envelope further includes a bonding element positioned on the first wall and / or second wall and configured to seal first wall to the second flexible wall to close the pocket opening.

[0021] In another aspect of the disclosed technology, the bonding element is positioned on an interior surface of first wall and / or the second wall.

[0022] In another aspect of the disclosed technology, the first wall and / or the second wall includes at least two overlying layers affixed to each other about an interlayer border that encloses a plurality of sides of an interlayer region defined by the at least two overlying layers.3169405775Docket No. 194313.18502

[0023] In another aspect of the disclosed technology, the first and second walls are flexible.

[0024] In another aspect of the disclosed technology, the envelope further includes a second gusset extending from the first wall, a second attachment lip extending from the second gusset, the second attachment lip overlaying and affixed to the exterior side of the envelope.

[0025] In another aspect of the disclosed technology, the first and second gussets cooperate to permit the first and second walls to move in relation to each other.

[0026] In another aspect of the disclosed technology, the first gusset is configured to contract and expand as the first and second walls move toward and away from each other in a first and second direction, and the first attachment lip as a transverse dimension in a third direction substantially perpendicular to the first and second directions.

[0027] In another aspect of the disclosed technology, an envelope for holding an item includes a first wall, a second wall overlying the first wall, and a first gusset having a first end extending from the first wall, and a second end attached to the second wall by a first seam displaced from the first gusset and located on an exterior side of the envelope. The first and second walls and the gusset cooperatively define a pocket located between the first and second walls, the pocket configured and dimensioned to contain the item, and a pocket opening allowing access to the pocket from an exterior of the envelope for loading the item into the pocket.

[0028] In another aspect of the disclosed technology, the first seam is defined by a first attachment lip extending from the second end of the first gusset.

[0029] In another aspect of the disclosed technology, the first end of the first gusset is unitary with the first wall.

[0030] In another aspect of the disclosed technology, the first seam is further defined by a bonding element affixing the first attachment lip to the second wall.4169405775Docket No. 194313.18502

[0031] In another aspect of the disclosed technology, the first gusset is devoid of any seams.

[0032] In another aspect of the disclosed technology, the first gusset is configured to contract and expand as the first and second walls move toward and away from each other in a first and second direction, and the seam is displaced from the first gusset in a third direction substantially perpendicular to the first and second directions.

[0033] In another aspect of the disclosed technology, the envelope further includes a second gusset having a first end extending from the first wall, and a second end attached to the second wall by a second seam displaced from the second gusset and located on an exterior side of the envelope.

[0034] In another aspect of the disclosed technology, web of pre-formed envelopes includes a first ribbon of material having a first fold, and a second fold located between the first fold and a first longitudinal edge of the first ribbon, the first and second folds defining a first gusset, the first ribbon having a first attachment lip defined between the first gusset and a first longitudinal edge of the first ribbon.

[0035] The web also includes a second ribbon of material overlayed on the first ribbon so that a portion of the second ribbon adjacent a first longitudinal edge of the second ribbon is positioned on the first gusset, and the first attachment lip extends transversely beyond the first longitudinal edge of the second ribbon.

[0036] In another aspect of the disclosed technology, the web further includes a bonding element located on the first attachment lip.

[0037] In another aspect of the disclosed technology, the web further includes a bonding element extending transversely across a substantial entirely of a width of the first ribbon.5169405775Docket No. 194313.18502

[0038] In another aspect of the disclosed technology, the first and second folds extend in a longitudinal direction of the first ribbon.

[0039] In another aspect of the disclosed technology, the first ribbon has a third fold, and a fourth fold located between the third fold and a second longitudinal edge of the first ribbon, the third and fourth folds defining a second gusset, the first ribbon having a second attachment lip defined between the second gusset and a second longitudinal edge of the first ribbon. A portion of the second ribbon adjacent a second longitudinal edge of the second ribbon is positioned on the second gusset, and the second attachment lip extends transversely beyond the second longitudinal edge of the second ribbon.

[0040] In another aspect of the disclosed technology, a method of forming an envelope includes folding a first ribbon of material about a first fold line, and folding the first ribbon about a second fold line located between the first fold line and a longitudinal edge of the first ribbon, the first and second fold lines defining a first gusset.

[0041] The method also includes overlaying a second ribbon of material on the first ribbon so that a portion of the second ribbon adjacent a first longitudinal edge of the second ribbon is positioned on the first gusset, and an attachment lip defined on the first ribbon between the first gusset and a first longitudinal edge of the first ribbon extends transversely beyond the first longitudinal edge of the second ribbon.

[0042] The method further includes folding the first attachment lip so that the first attachment lip overlaps the second ribbon, and affixing the first attachment lip to the second ribbon.

[0043] In another aspect of the disclosed technology, the method further includes folding the first attachment lip over the second ribbon.6169405775Docket No. 194313.18502

[0044] In another aspect of the disclosed technology, the method further includes folding the first attachment lip by about 180 degrees.

[0045] In another aspect of the disclosed technology, the method further includes folding the first attachment lip onto the second ribbon.

[0046] In another aspect of the disclosed technology, the method further includes pressing the first attachment lip into the second ribbon after folding the first attachment lip onto the second ribbon.

[0047] In another aspect of the disclosed technology, the method further includes affixing the first attachment lip to the second ribbon using a bonding element.

[0048] In another aspect of the disclosed technology, the method further includes applying the bonding element to the first attachment lip, and folding the first attachment lip onto the second ribbon so that the bonding element contacts the second ribbon.

[0049] In another aspect of the disclosed technology, the method further includes forming the first and second fold lines along a longitudinal direction of the first ribbon.

[0050] In another aspect of the disclosed technology, the first fold line is located at a distance from the first longitudinal edge of the first ribbon equal to a combined width of the first gusset and the first attachment lip.

[0051] In another aspect of the disclosed technology, the method further includes providing a web of the material, and slitting the web of material to form the first and second ribbons of the material.

[0052] In another aspect of the disclosed technology, the method further includes slitting the web of material so that a width of the first web is greater than a width of the second web.7169405775Docket No. 194313.18502

[0053] In another aspect of the disclosed technology, the method further includes aligning the second ribbon with the first ribbon in a transverse direction of the first and second ribbons.

[0054] In another aspect of the disclosed technology, folding the first ribbon of material about the first fold line includes creasing the first ribbon along the first fold line using a rotary plow.

[0055] In another aspect of the disclosed technology, folding the first ribbon of material about the second fold line includes creasing the first ribbon along the second fold line using a stationary creaser.

[0056] In another aspect of the disclosed technology, the method further includes applying a bonding element transversely across at least one of the first and second ribbons, and pressing the first ribbon into the second ribbon to form a transverse seal between the first and second ribbons.

[0057] In another aspect of the disclosed technology, the method further includes applying a release coating to one of the first and second ribbons, and applying a bonding element to the release coating, the first ribbon, and / or the second ribbon so that the release coating and the bonding element face each other when the second ribbon is overlayed onto the first ribbon.

[0058] In another aspect of the disclosed technology, the method further includes forming a separation region in one of the first and second ribbons proximate the release coating.

[0059] In another aspect of the disclosed technology, forming a separation region in one of the first and second ribbons proximate the release coating includes cutting the first or the second ribbon, or forming a line of weakness in the first or the second ribbon.

[0060] In another aspect of the disclosed technology, the method further includes folding the first ribbon about a third fold line, and folding the first ribbon about a fourth fold line located between the third fold line and a second longitudinal edge of the first ribbon, the third and fourth fold lines defining a second gusset.8169405775Docket No. 194313.18502

[0061] The method also includes overlaying the second ribbon of material on the first ribbon so that a portion of the second ribbon adjacent a second longitudinal edge of the second ribbon is positioned on the second gusset, and a second attachment lip defined on the first ribbon between the second gusset and a second longitudinal edge of the first ribbon extends transversely beyond the second longitudinal edge of the second ribbon.

[0062] The method further includes folding the second attachment lip so that the second attachment lip overlaps the second ribbon, and affixing the second attachment lip to the second ribbon.

[0063] In another aspect of the disclosed technology, a system for forming an envelope includes a forming device configured to form a first and a second fold line in a first and a second ribbon, the first and second fold lines defining a first gusset in the first ribbon. The system also includes a folding device configured to fold a first attachment lip defined on the first ribbon between the first gusset and a longitudinal edge of the first ribbon over a second web. The second web is on the first web so that a first portion of the second web adjacent a longitudinal edge of the second web is positioned on the first gusset.

[0064] In another aspect of the disclosed technology, the forming device incudes a rotary plow configured to form the first fold line.

[0065] In another aspect of the disclosed technology, the forming device further includes a first brush configured to cooperate with the rotary plow to form the first fold line.

[0066] In another aspect of the disclosed technology, the forming device further includes a stationary creaser configured to form the second fold line.

[0067] In another aspect of the disclosed technology, the forming device further includes a second brush configured to cooperate with the stationary creaser to form the second fold line.9169405775Docket No. 194313.18502

[0068] In another aspect of the disclosed technology, the folding device is configured to rotate the first attachment lip over the second ribbon.

[0069] In another aspect of the disclosed technology, the folding device is configured to rotate the first attachment lip onto the second ribbon.

[0070] In another aspect of the disclosed technology, the folding device is configured to rotate the first attachment lip by about 180 degrees.

[0071] In another aspect of the disclosed technology, the system further includes a slitter configured to slit a web of material to form the first and second ribbons.

[0072] In another aspect of the disclosed technology, the system further includes an aligner configured to align the second ribbon with the first ribbon in a transverse direction of the first and second ribbons.

[0073] In another aspect of the disclosed technology, the system further includes a first glue applicator configured to apply a bonding element to the first attachment lip of the first ribbon.

[0074] In another aspect of the disclosed technology, the first glue applicator is further configured to apply the bonding element in a band extending transversely across the first ribbon.

[0075] In another aspect of the disclosed technology, the system further includes a releasecoating applicator configured to apply a release coating to the first ribbon or the second ribbon.

[0076] In another aspect of the disclosed technology, the system further includes an ultraviolet light configured to cure the release coating after application of the release coating to the first ribbon or the second ribbon.

[0077] In another aspect of the disclosed technology, the system further includes a second glue applicator configured to apply a bonding element to the release coating, the first ribbon, or the second ribbon so that the boding element face the release coating.10169405775Docket No. 194313.18502

[0078] In another aspect of the disclosed technology, the system further includes a first cutting device configured to separate or partially separate a portion of the first web or the second web containing the release coating from an adjacent portion of the first web or the second web.BRIEF DESCRIPTION OF DRAWINGS

[0079] The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

[0080] FIG. l is a perspective view of an envelope having a cover configured to cover a closure flap of the envelope, depicting the cover spaced from the closure flap for illustrative clarity;

[0081] FIG. 2 is a side view of the envelope shown in FIG. 1, depicting the cover spaced from the closure flap;

[0082] FIG. 3 is a cross-sectional view of the envelope shown in FIGS. 1 and 2;

[0083] Fig. 4 is a perspective view of a web of the envelopes shown in FIGS. 1-3;

[0084] FIG. 5 is a perspective view the envelope shown in figs 1-3, with the cover of the envelope removed to facilitate closing and sealing of the envelope;

[0085] FIG. 6 is a perspective view of the envelope shown in FIGS. 1-5, depicting the envelope in a closed and sealed condition and holding an item;

[0086] FIG. 7 is a cross-sectional view of the envelope shown in FIGS. 1-6, taken through the line VII- VII of FIG. 6;

[0087] FIG. 8 is a front view of an alternative embodiment of the envelope shown in FIGS. 1-6, depicting a closure flap of the envelope in an open position;11169405775Docket No. 194313.18502

[0088] FIG. 9 is a diagrammatic view of a system used to form the envelope shown in FIG. 8;

[0089] FIG. 10 is a perspective view of a gusset forming unit of the system shown in FIG. 9;

[0090] FIG. 11 is a cross-sectional view taken through the line XI-XI of FIG. 10;

[0091] FIG. 12 is a cross-sectional view taken through the line XII-XI1 of FIG. 10;

[0092] FIG. 13 is a cross-sectional view taken through the line XIII-XIII of FIG. 10;

[0093] FIG. 14 is a perspective view of a gusset and seam former of the gusset forming unit shown in FIG. 10;

[0094] FIG. 15 is a cross-sectional view of a first and a second ribbon of material overlaying each other immediately upstream of the gusset and seam former shown in FIG. 14;

[0095] FIG. 16 is a cross-sectional view of the ribbons overlaying each other downstream of the gusset and seam former shown in FIGS. 14 and 15, after outer panels of the first ribbon have been folded onto an upward-facing surface of the second ribbon to form seams;

[0096] FIG. 17 is a cross-sectional view of the gusset and seam former shown in FIGS. 14-16, showing the gusset and seam former overturning one of the outer panels of the first ribbon; and

[0097] FIGS. 18 and 19 are front views of the ribbons shown in FIGS. 9-17.DETAILED DESCRIPTION

[0098] The inventive concepts are described with reference to the attached figures, wherein like reference numerals represent like parts and assemblies throughout the several views. Several aspects of the inventive concepts are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the inventive concepts. One having ordinary skill in the relevant art, however, will readily recognize that the inventive concepts can be practiced12169405775Docket No. 194313.18502without one or more of the specific details or with other methods. In other instances, well-known structures or operation are not shown in detail to avoid obscuring the inventive concepts.

[0099] Directional terms such as “top,” “bottom,” “upper,” “lower,” etc. are used in relation to the component orientations depicted in FIG. 1. These terms are used for illustrative purposes only and are not intended to limit the scope of the appended claims.

[0100] Figs. 1-3 and 5-8 depict an envelope 10. The envelope 10 is configured to contain and hold an item 11 to be packaged. The envelope 10 typically encloses the item 11 while the item 11 is being mailed, shipped, or otherwise needs to be packaged in a closed container. The item 11 is depicted in phantom in FIG. 6.

[0101] Packaging articles include, for example, packaging containers, protective packaging articles, and thermal insulation articles. Packaging containers can include parcel packaging and other containers to package items. Packaging containers are configured to contain and hold an item, typically enclosing the item, during shipping or storage of the item. Parcel packaging is configured for shipping and / or storing products, such as for storage in warehouse or retail shelves and displays. Examples of parcel packaging include flexible shipping containers such as envelopes, which can have varying degrees of flexibility and typically are used to ship or mail small or relatively flat items or smaller items around which the walls of the container can conform envelopes. Flexible shipping containers such as envelopes can be padded or nonpadded, can be made of materials such as paper and flexible cardboard, can be configured with or without sidewalls or gussets, and can include larger envelopes such as mailers. Examples of parcel packaging also include bags, such as paper or poly bags, which can have a self-sealing capability and are typically used to ship small to medium-sized items; boxes, which can be formed from paperboard, cardboard, wood, or plastic, and typically have a rigid or semi-rigid 13169405775Docket No. 194313.18502structure suitable for holding medium to large-size items and heavier items; and shipping tubes or tube mailers, typically used to ship documents and paper items.

[0102] The term “envelope,” as used herein, is intended to encompass, without being limited to, flat shipping containers, including mailers, typically used to ship or mail smaller items and having sufficient flexibility so as to expand and bend around the item 11 upon insertion of the item 11 into a pocket within the envelope 10; and in which the sidewalls or thickness of the container are substantially smaller than, e.g., less than 1 / 100th (one percent) of, the width and / or height of the container.

[0103] The envelope 10 comprises an envelope body 13 that includes a wall 12, an opposing wall 14, and two side gussets 33. Each side gusset 33 in connected to the wall 12 and the wall 14, as can be seen in FIG. 3. The wall 12 is visible in FIGS. 3, 5, and 7.

[0104] Each side gusset 33 facilitates expansion of the envelope body 13 by permitting the walls 12, 14 to move away from each other. The walls 12, 14 and the gussets 33 define an internal containment area or envelope pocket 15 that receives the item 11 being held within the envelope 10. The envelope pocket 15 is accessible by way of an opening 17 defined by the walls 12, 14 and the gussets 33 at the top of the envelope body 13. The opening 17 is denoted in FIG.5. The envelope pocket 15 is visible in FIGS. 3 and 7.

[0105] The envelope 10 also includes a closure flap 42. The closure flap 42 is unitarily formed with the wall 12 and adjoins an upper edge of the wall 12 as can be seen in FIGS. 2 and 5. A score line 46 is formed at the interface of the closure flap 42 and the wall 12. The score line 46, visible in FIG. 5, causes the underlying portion of the envelope material to act as a living hinge that allows the closure flap 42 to rotate between an open position shown in FIGS. 1-3 and 5, and a closed position shown in FIGS. 6 and 7.14169405775Docket No. 194313.18502

[0106] When in the open position, the closure flap 42 allows the envelope pocket 15 to be accessed via the opening 17 between the walls 12, 14, so that the item 11 can be inserted into the envelope pocket 15. When in the closed position, the closure flap 42 covers the opening 17 and thereby maintains the opening 17 in a closed state, so that the item 11 is retained within the envelope 10.

[0107] A bonding element in the form of a closure sealing element 24 is disposed on the closure flap 42, as shown in FIGS. 1-3 and 5. The closure sealing element 24 is configured to bond to the outwardly facing surface of the wall 14 when the closure flap 42 is in its closed position, thereby fixing the closure flap 42 in the closed position and maintaining the opening 17 in its closed state.

[0108] The closure sealing element 24 can be, for example, a pressure-sensitive hot-melt adhesive with sufficient tackiness at room temperature to form a bond that fixes the closure flap 42 to the wall 14 of the envelope 10 as discussed below.

[0109] Hot-melt adhesives are thermoplastic polymers that are solid at room temperature, become molten when heated to a temperature above their softening point, and resolidify by loss of heat, increasing in strength as they resolidify. Most hot-melt adhesives, upon melting into a molten state and re-solidifying, do not undergo any chemical reaction such as cross-linking or removal of a carrier, e g., evaporation of water. Thus, hot-melt adhesives typically can be reactivated, i.e., re-melted and re-solidified, after initially being applied to a substrate.

[0110] Some hot-melt adhesives can have minimal, or no tackiness when in their solid form, so that the hot-melt adhesive, after initially being applied to a substrate and cooling, does not bond or otherwise adhere to another substrate or object, or to the skin of a user coming into contact with the hot-melt adhesive. In applications in which some degree of tackiness at room15169405775Docket No. 194313.18502temperature or other temperature ranges is desired, tackifiers or tackifying agents can be added to the hot-melt adhesive in an amount sufficient to achieve the desired level of tackiness.

[0111] The hot-melt adhesive of the closure sealing element 24, upon melting into a molten state and re-solidifying, does not undergo any chemical reaction such as cross-linking or removal of a carrier, e.g., evaporation of water. Thus, the hot-melt adhesive can be re-activated, i.e., heated to re-melt, followed by re-solidification, after initially being applied to the wall 12 or other substrate. The hot-melt adhesive, upon re-melting and re-solidifying, can embed itself into the paper fibers of the wall 14, creating the bond strength that adheres the wall 14 to the wall 12.

[0112] Other types of bonding elements can be used as the closure sealing element 24 in alternative embodiments. For example, the closure sealing element 24 can be a pressure sensitive cold adhesive in alternative embodiments. In other alternative embodiments, for example, the closure sealing element 24 can be a heat-seal material. In the case of paper substrates to be fixed to each other, a heat-seal material may be applied to each of the substrates. At the time the substrates are to be fixed, the heat-seal material on one or both of the substrates is subject to heat and pressure sufficient to weld the heat-seal materials together, thereby fixing the paper substrates to each other.

[0113] Referring to FIGS. 1-3, the envelope 10 also includes a cover 44. The cover 44 covers the closure flap 42 before the closure flap 42 is closed and sealed as can be seen in FIG. 3. The cover 44 comprises a substrate 47 covered by a release coating 48. The release coating 48 is configured to lightly adhere to the closure sealing element 24 on the closure flap 42, so that the cover 44 will be retained on the closure flap 42 until the user removes the cover 44. In particular, the release coating 48 is configured so that adhesion between the release coating 48 and the closure sealing element 24 is sufficient to prevent the cover 44 from falling off of, or 16169405775Docket No. 194313.18502easily separating from the closure flap 42, but low enough to allow the cover 44 to be pulled or otherwise separated from the closure flap 42 without removing, tearing, or otherwise damaging the closure sealing element 24, the closure flap 42, or any other part of the envelope 10.[00114J The cover 44 has a shape and dimensions that approximately match the shape and dimensions of the closure flap 42. The cover 44 can have a shape and dimensions that do not match those of the closure flap 42 in alternative embodiments.

[0115] In some embodiments, the release coating 48 can be, for example, a silicone material. In other embodiments, the release coating 48 can be, for example, a UV curable release material. In other embodiments, the release coating 48 can be, for example, a UV-curable cationic release silicone. In other embodiments, the release coating 48 can be, for example, a UV curable silicon release material such as Elkeem UV POLY 206. The release coating 48 can be formed from other materials and other compositions in other alternative embodiments.

[0116] The release coating 48 can cover the entire inwardly facing surface of the cover 44. In alternative embodiments, the release coating 48 can be applied only to the portion of the cover 44 that opposes the closure sealing element 24 when the closure flap 42 is moved to its closed position. In other alternative embodiments, the release coating 48 can cover the entire surface of the ribbon from which the wall 14 and the cover 44 are formed.

[0117] The wall 14, the cover 44, and the gussets 33 can be formed from a ribbon 32b of extensible paper, depicted in FIG. 4. The wall 12 and the closure flap 42 can be formed from a ribbon 32b of extensible paper, also depicted FIG. 4 in an assembled state with the ribbon 32a. The basis weight of the paper is application-dependent and can vary with factors such as the load to which the envelope 10 will be subjected when loaded with the item 11. In some embodiments, the paper can be a single ply of 55-pound (ream weight) paper sold by Canadian 17169405775Docket No. 194313.18502Kraft Paper Industries Ltd. of Manitoba, Canada, as “SPX® extensible Kraft paper,” which has a stretch, i.e., extensibility, of about 6.8 percent in the machine direction and about 8.9 percent in the cross-machine direction; a tensile strength of about 45.7 Ibs / inch in the machine direction and about 33.1 Ibs / inch in the cross-machine direction; a tear strength of about 110 grams in the machine direction and about 120 grams in the cross-machine direction; and a TEA of about 19.2 ft-lb / ft2in the machine direction and about and 20.9 ft-lb / ft2in the cross-machine direction. Other types of paper can be used in the alternative. For example, the walls 12, 14 each can be formed from a single ply of 30-pound to 90-pound “SPX® extensible Kraft paper,” depending on the degree of strength of the walls 12, 14 required for a particular application. Other suitable weights can be used in other embodiments.

[0118] In alternative embodiments, one of the ribbons 32a, 32b can be formed from extensible paper, and the other ribbon 32a, 32b can be formed from regular (non-extensible) kraft paper, another type of non-extensible paper, or another type of material such as polyethylene. In other alternative embodiments, both ribbons 32a, 32b can be formed from non-extensible paper, sack paper, or any other suitable type of paper.

[0119] In applications where the extensibility and / or the TEA of the extensible paper are greater in the machine direction than in the cross-machine direction of the paper, the ribbons 32a, 32b of extensible paper can be oriented so that the machine direction of the paper coincides with the direction of the envelope 10 in which greater stretch and / or TEA is needed or otherwise desired. For example, the walls 12, 14 can be configured so that the machine direction of the extensible paper coincides with the transverse direction of the envelope 10, to facilitate maximal stretching of the walls 12, 14 proximate the envelope pocket 15, as the walls 12, 14 are spread apart to facilitate insertion of the item 11 into the envelope pocket 15 as discussed below.18169405775Docket No. 194313.18502Conversely, in applications where the stretch and / or the TEA of the extensible paper is greater in the cross-machine direction than in the machine direction of the paper, the ribbons 32a, 32b can be oriented so that the cross-machine direction of the paper coincides with the direction of the envelope 10 in which greater stretch and / or TEA are needed or otherwise desired.

[0120] Also, the ribbons 32a, 32b can be oriented so that the machine and cross-machine directions do not align with either of the longitudinal or transverse directions of the envelope 10. For example, the extensible paper of the ribbons 32a, 32b can be oriented so that the machine and cross-machine directions of the paper are diagonal to the longitudinal and transverse directions of the envelope 10, i.e., the extensible paper can be oriented so that the machine and cross-machine directions of the paper are offset from the longitudinal and transverse directions of the envelope 10 by about 45 degrees.

[0121] The longitudinally extending side-edge portions of the ribbon 32a define attachment lips 60 that form side seams on the respective sides of the envelope 10. The attachment lips 60 are located outward of the portions of the ribbon 32a that form the respective gussets 33. A discussed below, the attachment lips 60 are folded over, and onto the outwardly facing surface of the wall 12 and are fixed to the outwardly facing surface of the wall 12 to connect the wall 12 to the gussets 33 and the wall 14.

[0122] The envelope 10 also includes two longitudinal seals 16, and a transverse seal 18. The longitudinal seals 16 fix the attachment lips 60 to the wall 14, and thus are located beneath the attachment lips 60, from the perspective of FIG. 1. The transverse seal 18 fixes the bottom of the wall 14 to the bottom of the wall 12 and is visible in FIGS. 3 and 7. The longitudinal seals 16 and the transverse seals 18 are formed from a bonding element in the form of, for example, a pressure-sensitive cold adhesive. Other types of bonding elements and other types of adhesives,19169405775Docket No. 194313.18502such as a heat-sealable material or a hot-melt adhesive, can be used lieu of the pressure-sensitive adhesive in alternative embodiments.

[0123] The wall 12, the wall 14, the longitudinal seals 16, and the transverse seals 18 define a pocket border that encloses the envelope pocket 15. The closure flap 42 forms another portion of the pocket border when the closure flap 42 is folded to its closed position shown in FIGS. 6 and 7.

[0124] The release coating 48 is applied to the ribbon 32a at the respective locations corresponding to the locations at which the release coating 48 will be located on the completed envelopes 10. Likewise, the closure sealing elements 24 are applied to the ribbon 32b at the respective locations corresponding to the locations at which the closure sealing elements 24 will be located on the completed envelopes 10. Alternatively, the closure sealing elements 24 can be applied over the areas of release coating 48 on the ribbon 32a, and can be transferred to the ribbon 32b when the ribbons 32a, 32b are joined to each other.

[0125] Also, the bonding element that forms the longitudinal and transverse seals 16, 18 is applied to the ribbon 32a at the respective locations at which the longitudinal and transverse seals 16, 18 will be located once the ribbons 32a, 32b have been joined to form a web 78 of envelopes 10. And the score lines 46 are formed in the ribbon 32b at the respective locations corresponding to the locations at which the score lines 46 will be located on the completed envelopes 10.

[0126] During assembly of the web 78, the ribbons 32a, 32b are aligned after the ribbon 32a has been folded to define the gussets 33 (the folding process is described below). The ribbons 32a, 32b are aligned so that each patch of release coating 48 on the ribbon 32s aligns with a corresponding closure sealing element 24 on the ribbon 32b; and each side edge portion of the 20169405775Docket No. 194313.18502ribbon 32b aligns with the folded material on the ribbon 32a that defines a respective one of the gussets 33. The ribbons 32a, 32b are then brought into contact with each other, and the attachment lips 60 are folded over and onto the outwardly facing surface of the ribbon 32b that will form the wall 12 in the fully-formed envelopes 10, so that the bonding element on the attachment lips 60 forms the longitudinal seals 16 that bond the gussets 33 and the adjoining wall 14 to the wall 12. Also, the transversely extending strips of the bonding element, upon coming into contact with the inwardly facing surface of the wall 12, form the transverse seal 18 that bonds the bottom of the wall 12 to the bottom of the wall 14.

[0127] Thus, the seam that connects each gusset 33 to the wall 12 is defined by the attachment lip 33, the wall 12, and the longitudinal seal 16 between the attachment lip 33 and the wall 12, and this seam is displaced from the gusset 33, making the gusset 33 devoid of any seams. It is believed that forming the seam between the wall 12 and the attachment lip 33 can provide the gusset 33 with better resistance to tearing and other damage, and results in a more secure connection to the wall 12, in relation to an envelope in which the gusset 33 is connected directly to the wall 12.

[0128] Once the ribbons 32a, 32b have been joined in the above manner to form the web 78 of envelopes 10, kiss cuts 50 can be made through the ribbon 32a to define the cover 44 and the wall 14 of each envelope 10, with each cover 44 comprising a respective patch of the release coating 48, and the underlying portion of the paper from which the ribbon 32a is formed. The underlying paper thus forms a substrate on which the release coating 48 is disposed.

[0129] Each kiss cut 50 can be made in the ribbon 32a at a location corresponding to the top of the wall 14 and the bottom of the cover 44 of the corresponding envelope 10. Because the respective heights, or lengthwise dimensions of the walls 12, 14 are about equal, the kiss cut 5021169405775Docket No. 194313.18502is located approximately adjacent to a respective score line 46 between the wall 12 and the closure flap 42 on the ribbon 32b. The kiss cuts 50 are visible and FIGS. 1 and 4.

[0130] The kiss cuts 50 can extend through the underlying portions of the gussets 33. In alternative embodiments, the kiss cuts 50 can be configured to not extend through the underlying portions of the gussets 33.

[0131] Each kiss cut 50 defines the boundary between the wall 14 and the cover 44 of the corresponding envelope 10 and permits the cover 44 to be removed from the envelope 10 when the envelope 10 is to be loaded and sealed. As noted above, the release coating 48 on the cover 44 is configured to adhere to the closure sealing element 24 to prevent the cover 44 from falling off of, or easily separating from the closure flap 42, while allowing the cover 44 to be removed from the closure flap 42 without tearing or otherwise damaging the closure flap 42 or any other part of the envelope 10. Thus, the cover 44 will remain on the envelope 10 prior to the loading and sealing of the envelope 10, thereby preventing the closure sealing element 24 on the closure flap 42 from contacting and adhering to other objects such as adjacent envelopes 10 in a stack of the envelopes 10. Also, the closure sealing element 24 should retain its ability to form a closure seal 54 that fixes the closure flap 42 to the wall 12 with sufficient strength to maintain the closure flap 42 in its closed position after the item 11 has been loaded into the envelope 10 and as the envelope 10 is being shipped and handled. The requisite strength of the closure seal 54 is application-dependent, and can vary with factors such as the size of the envelope 10 and the closure seal 54, the size and weight of the item 11, the properties of the paper or other material from which the envelope 10 is formed, etc. An appropriate closure sealing element 24 can be selected for a particular application using the knowledge generally attributed to those of ordinary skill in the field of adhesives technology.22169405775Docket No. 194313.18502

[0132] The longitudinal seals 16, which underlie the respective attachment lips 60, extend continuously along the respective side edge portions of the envelope 10. The longitudinal seals 16 can be non-continuous in alternative embodiments.[00133J The transverse seal 18 extends continuously along the bottom edge 22 of the envelope 10 in the transverse direction and intersects the longitudinal seals 16. The transverse seal 18 can be offset from the bottom edge 22 of the envelope 10 in alternative embodiments. Also, the transverse seal 18 can extend over a distance less than the distance between the longitudinal seals 16, and / or can be non-continuous in alternative embodiments.

[0134] In alternative embodiments, the bottom portion of the inner surface of the wall 14 can be folded over and onto the bottom portion of the wall 12 to create a fold that reinforces the bottom of the envelope 10.

[0135] In alternative embodiments, the envelope 10 can include an additional gusset 33 that extends along the bottom portion of the envelope 10, i.e., adjacent to the bottom edge 22 of the envelope 10. In other alternative embodiments, the gussets 33 and the attachment lips 60 can be unitarily formed with the wall 12 instead of the wall 14. In other alternative embodiments, the envelope 10 can be formed without the gussets 33.

[0136] The attachment lips 60 can have a width, or transverse dimension of, for example, about 0.25 inch to about 1.0 inch. The attachment lips 60 can have a width above or below this range in alternative embodiments. The longitudinal and transverse seals 16, 18 can have a width, for example, similar to that of the attachment lips 60.

[0137] In other alternative embodiments, the wall 12 and the closure flap 42 can be formed from two of the ribbons 32b affixed to each other; and the wall 14, gussets 33, and attachment lips 60 can be formed from two of the ribbons 32a affixed to each other. In such embodiments,23169405775Docket No. 194313.18502the wall 12 and the wall 14 each have two layers affixed to each other about an interlayer border that encloses a plurality of sides of an interlayer region defined by the overlying layers. In some embodiments, the two overlying layers can be unadhered to each other within at least a portion of the interlayer region, and the interlayer region can be empty so that the overlying layers abut each other over a majority of the interlayer region.

[0138] The two layers of each wall 12, 14 can be affixed to each other by two longitudinal inter-layer seals and two transverse inter-layer seals formed from a bonding element in the form of an adhesive material. The longitudinal inter-layer seals can be located along longitudinal edges of the respective walls 12, 14, and extend substantially in a longitudinal direction of the walls 12, 14. Each longitudinal inter-layer seal can be offset from the corresponding edge of the wall 12 or the wall 14 in the alternative. The longitudinal inter-layer seals can be continuous. The longitudinal inter-layer seals can be non-continuous in the alternative. The transverse interlayer seals can be located along the lower and upper edges of the walls 12, 14, and extend substantially in a transverse direction of the walls 12, 14, between the longitudinal inter-layer seals. The transverse inter-layer seals can be offset from the lower and upper edges of the wall 12 or the wall 14 in the alternative. The transverse inter-layer seals are continuous. The transverse inter-layer seals can be non-continuous in the alternative.

[0139] An angled cut and an adjoining transverse cut can be made through each envelope 10 on each side of the cover 44 and each side of the closure flap 42 to form a triangular cutouts on each side the cover 44 and the closure flap 42. The cutouts, in conjunction with the kiss cuts 50, permit the cover 44 to be separated from the closure flap 42 as discussed below. The cutouts give the cover 44 and the closure flap 42 a trapezoidal shape. The cover 44 and the closure flap 42 can have other shapes in alternative embodiments.24169405775Docket No. 194313.18502

[0140] Once the web 78 of envelopes 10 has been assembled as discussed above, the individual envelopes 10 be separated from the web 78 by a suitable technique such as cutting, the focused applicant of heat, etc. In alternative embodiments, a line of weakness, such as a series of perforations, can be formed between the individual envelopes 10 in the web 78 so that the envelopes 10 can be separated from the web 78 by tearing the envelopes 10 along the line of weakness.

[0141] When the envelope 10 is to be loaded and sealed, the user can remove the cover 44 by pulling the cover 44 to separate the release coating 48 on the cover 44 from the closure sealing element 24 and thereby expose the closure sealing element 24. The wall 14 then can be pulled away from the wall 12 to define the envelope pocket 15 and the opening 17 that leads thereto. The item 11 can be placed in the envelope pocket 15, and the closure flap 42 can be folded from its open position to its closed position, to bring the closure sealing element 24 into contact with the outwardly facing surface of the wall 14. Alternatively, the cover 44 can be removed after the item 11 has been loaded into the envelope pocket 15, to help avoid inadvertent contact between the item 11 and the closure sealing element 24. Once the closure flap 42 has been moved to its closed position, the user can press the closure flap 42 into the adjacent portion of the wall 14 so that the closure sealing element 24 forms a closure seal 54 that fixes the closure flap 42 to the wall 12, thereby securing the item 11 in the envelope pocket 15. The closure seal 54 is depicted in FIGS. 6 and 7. (In applications where the closure sealing element 24 requires reactivation, the closure sealing element 24 can be heated, and the closure flap 42 and the adjacent portion of the wall 14 can be pressed together to form the closure seal 54.)

[0142] In alternative embodiments, the cover 44 can remain attached to the wall 14 by way of a line of weakness, formed by perforations, scoring, or another suitable technique, that permits 25169405775Docket No. 194313.18502the cover 44 to be removed from the wall 14 without tearing or otherwise damaging the wall 14 during the loading process for the envelope 10. For example, alternative embodiments of the envelope 10 can include perforations in lieu of the kiss cut 50. In other alternative embodiments, instead of removing the cover 44, the user can fold the cover 44 inwardly and into the envelope pocket 1 along the line of weakness, to expose the closure sealing element 24 so that the envelope 10 can be sealed closed. In such applications, the cover 44 can remain attached to the envelope 10 and inside of the envelope pocket 15 after the closure flap 42 has been folded into its closed position and the envelope 10 has been sealed closed.

[0143] The use of the cover 44 eliminates the need to place a release strip over the closure sealing element 24 to isolate the closure sealing element 24 from contact with other objects prior the loading and sealing of the envelope 10. Because the cover 44 is formed along with the wall 12, and from the same ribbon 32a of paper material as the wall 14, the number and complexity of the production steps needed to form the envelope 10 are less than those of a production process for a comparable envelope in which a separate release strip needs to be placed over the closure sealing element of the envelope. Thus, the use of the cover 44 can facilitate higher production speeds and reduced scrap / downtime.

[0144] In alternative embodiments, one or both walls 12, 14 can include one or more functional layers positioned thereon. Examples of functional layers can include, but are not limited to, waterproofing layers (configured to reduce permeability of water therethrough), an airtight layer (configured to reduce permeability of air therethrough), other suitable material layers, and / or a combination thereof.

[0145] In other alternative embodiments, one or both walls 12, 14 can have a multi-ply configuration. For example, the walls 12, 14 each can be formed from two plies of relatively low 26169405775Docket No. 194313.18502basis-weight paper, such as two plies of 30 to 45-pound paper. The two plies of 30 to 45-pound paper can be used in lieu of a single ply of 90-pound paper. In some embodiments, padding, cushioning, or insulating material can be disposed between the plies of one or both multi-ply walls 12, 14. In other embodiments, the space between the plies can remain empty.

[0146] In other alternative embodiments, the envelope 10 can be configured without the cover 44, and the closure sealing element 24 can be covered by a conventional release strip.

[0147] FIG. 8 depicts an alternative embodiment of the envelope 10 in the form of an envelope 10a. The above description of the envelope 10a applies to the envelope 10 unless otherwise noted, and identical refence numbers are used to describe identical or substantially identical portions of the envelope 10a and the envelope 10.

[0148] The envelope 10a is identical to the envelope 10, with the following exceptions. The gussets 33 and the attachment lips 60 of the envelope 10a are unitarily formed with the wall 12 instead of the wall 14, and the attachment lips 60 are affixed to the wall 14.

[0149] Also, the envelope 10a includes a closure flap 42a and a cover 44a in which C-shaped cuts 160 are formed in the closure flap 42a, the cover 44a, the walls 12, 14, the gussets 33, and the attachment lips 60. The cuts 160 extend through the score line 46 about which the closure flap 42 rotates. Each C-shaped cut 160 defines cutouts 162 at the upper corners of a corresponding gusset 33. The cutouts 162 provide stress relief for the gussets 33 and the adjoining walls 12, 14 when the envelope 10a is opened, i.e., when the wall 12 is pulled away from the wall 14 to form the opening 17.

[0150] Also, the envelope 10a includes two holes 118 that are formed in the portion of the closure flap 42a located between the upper edge of the closure sealing element 104 and the upper edge 116 of the closure flap 42a. The holes 118 can receive the respective legs of a wicket (not 27169405775Docket No. 194313.18502shown) that permits a grouping, or flight of the envelopes 10a to be suspended the wicket. The wicket can be installed, for example, on a wall or backing board at or near a packing table, so that a packer can retrieve the envelopes 10a from the wicket on an individual basis as the envelopes 10a are needed to package items. An envelope 10a can be retrieved from the wicket, for example, by pulling the envelope 10a downward so that the legs of the wicket rip the closure flap 42a between the holes 118 and the upper edge 116 of the closure flap 42a.

[0151] The closure flap 42a and the cover 44a each have a U-shaped 119 cut formed therein. The cuts 119 are centered around the longitudinal centerline of the envelope 10a, and ends of the cuts 119 are spaced from the upper edges of the closure flap 42a and the cover 44a by, for example, about 1 / 8 inch. Multiple envelopes 10a can be stacked and fastened to each other by a fastener, such as a staple, inserted through the portions of the flaps 42a and covers 44a within the U-shaped cut 119, thereby connecting the multiple envelopes 10a into a flight of the envelopes 10a. The staple, and the surrounding portions of the closure flaps 42a and the covers 44a defined by the cuts 119, can be removed collectively from the flight immediately before, or after the flight is loaded onto the wicket by a user. The user can grasp the region on the flight defined within the cuts 119, and can pull or twist the region to tear the material between the ends of the cuts 119 and the upper edges of the closure flaps 42a and the covers 44a, thereby removing the staple from the flight and disconnecting the individual envelopes 10a within the flight from each other.

[0152] FIGS. 9 to 17 depict a system 500 for forming the envelopes 10a. The system 500 also can be used to form the envelopes 10, and the following description of the formation of the envelopes 10a is generally applicable to the envelopes 10.28169405775Docket No. 194313.18502

[0153] The system 500 includes an unwinder 502, a printing unit 504, a labeling unit 506, and a slitting unit 508. The system 500 also includes a coating and curing station 512, a ribbon aligner 514, a glue applicator 516, and a gusset forming unit 510. The system 500 further includes a ribbon aligner 514, a coating and curing station 512, a glue applicator 516, a glue applicator 518, a gusset and seam former 520, a die cutter 522, and a rotary cutter 524.

[0154] The ribbons 32a, 32b can be formed from a single sheet of stock material 526, e.g., regular kraft paper, that is separated into the first and second ribbons 32a, 32b in the slitting unit 508. Except where otherwise noted, the above components of the system 500 are relatively positioned so that the stock material 526 and the ribbons 32a, 32b travel between, and through the components in a downstream direction.

[0155] The stock material 528 can be provided as a roll 528 the stock material 526. The unwinder 502 is configured to hold two of the rolls 528, and to unwind one of the rolls 528 while maintaining substantially constant tension in the stock material 526 as it is unwound and drawn to the printing unit. The unwinder 502 also is configured to automatically splice the training end of the stock material 526 an expiring roll 528 to the leading end of the stock material 526 in a new roll 528.

[0156] The printing unit 504 is configured to receive the stock material 526 being unwound from the roll 528, and to print a predetermined set of markings at predetermined locations on the stock material 526. The markings can include registrations marks. The registration marks, as discussed below, are used to index the ribbons 32a, 32b to various components of the system 500 as the ribbons 32a, 32b are processed into the envelopes 10. The printing unit 504 can be, for example, a flexographic printer. Other types of printers can be used in alternative embodiments of the system 500.29169405775Docket No. 194313.18502

[0157] The labeling unit 506 is configured to receive the stock material 526 from the printing unit 504, and to place predetermined labels at preselected locations on the stock material 526.

[0158] The slitting unit 508 is configured to receive the stock material 526 from the labeling unit 506, with the side of stock material 526 having the previously applied printing and / or labeling thereon facing upward. The slitting unit 508 is configured to cut the stock material 526 into the ribbons 32a, 32b, and to flip ribbon 32a over after it is formed so that the side of the ribbon 32a with the printing and / or labeling faces downward. The slitting unit 508 has the capability to simultaneously process two sheets of the stock material 526 to produce four ribbons of stock material. This capability can be used in applications where an envelope with two-ply walls is being produced, with the plies of each wall formed from two of the ribbons overlaid onto each other.

[0159] The slitting unit 508 includes two rotary slitters 530. Upon entering the slitting unit 508, the stock material 526 directed over rollers 532 that lower the path of the stock material 526 and place the stock material 526 in a horizontal orientation proximate to the bottom of the slitting unit 508. The stock material 526 is then directed over an elongated guide 534 oriented at an angle of about 45 degrees in relation to the direction of travel of the stock material 526 as it approaches the guide 534. The guide 534 changes the direction of travel of the stock material 526 by about 90 degrees, with the direction of travel remaining generally horizontal.

[0160] The stock material 526 is subsequently directed to another roller 532, which changes the direction of travel of the stock material from horizontal to generally vertical. The stock material 526 contacts a first of the rotary slitters 530 as it travels upward after being turned. The rotary slitter 530 cuts the stock material 526 to form the ribbons 32a, 32b. (Because the walls30169405775Docket No. 194313.1850212, 14 of the envelopes 10 are single-ply walls, the second rotary slitter 530 is not used in the particular application.)

[0161] The position of the first rotary slitter 530 is adjusted so that the ribbon 32a, from which the gussets 33 and the walls 12 of the envelopes 10 will be formed, is wider than the ribbon 32b, which will be used to form the walls 12. In applications where the envelopes being produced from the ribbons 32a, 32b will not have side gussets, the rotary slitter 530 can be positioned so that the ribbons 32a, 32b are of substantially equal width.

[0162] Immediately after being formed, the ribbons 32a, 32b are turned back into a generally horizontal path of travel by another roller 532, with the new direction being offset from the downstream direction by about 90 degrees. The ribbon 32b subsequently is directed to another guide 234 oriented at an angle of about 45 degrees in relation to the direction of travel of the ribbon 32b. The guide 534 alters the direction of travel of the ribbon 32b, so that the ribbon 32b is drawn in the downstream direction to the ribbon aligner 514.

[0163] The ribbon 32b, after being turned to a horizontal path of travel, is turned by about 180 degrees by another roller 532. The ribbon 32b then travels to the coating and curing station 512 along a downward- si oping path, in a direction generally transverse to the downstream direction.

[0164] The coating and curing station 512 is configured to apply the UV-curable release coating 48 to the ribbon 32b, and to cure the release coating 48 after application. The coating and curing station 512 includes a coater 538, and a curing unit 540.

[0165] The coater 538 is configured to apply the release coating 48 to the ribbon 32b at locations that will correspond to the covers 44 of the fully formed envelopes 10. The coater 538 includes a sensor configured to sense the registration marks printed on the ribbon 32b by the printing unit 504. The registration marks on the ribbon 38b permit the coater 538 to index the 31169405775Docket No. 194313.18502ribbon 32b to the coater 538 so that the coater can apply the release coating 48 at the proper locations on the ribbon 32b. The coater 538 can include an anilox roller and a doctor blade that meter the release coating 48 as it is applied to the ribbon 32b.[00166J The ribbon 32b is directed to the curing unit 540 after the release coating 48 has been applied to the ribbon 32b. The curing unit 540 is configured to subject the release coating 48 to UV light that cures the release coating 48. After leaving the curing unit 540, the ribbon 32b is turned by about 180 degrees by a roller 542. The ribbon 32b then travels back toward the coater 538, passes over coater 538, and travels back to slitting unit 508 in a direction of travel generally transverse to the downstream direction.

[0167] Upon returning to the slitting unit 508, the ribbon 32b is turned by about 90 degrees in a downward direction, and then about 90 degrees in an upward direction by two additional rollers 532. The ribbon 32b then is directed to another guide 534 that is oriented at an angle of about 45 degrees in relation to the direction of travel of the ribbon 32b. The guide 534 alters the direction of travel of the ribbon 32b by about 90 degrees, so that the ribbon 32b travels in a generally upstream direction.

[0168] The ribbon 32b subsequently is turned by about 180 degrees upon passing over another roller 532, so that the ribbon 32b is drawn in the downstream direction to the ribbon aligner 514.

[0169] The ribbon 32b is positioned above the ribbon 32a as the ribbons 32a, 32b reach the ribbon aligner 514. The ribbon aligner 514 is configured to align the ribbons 32a, 32b. In particular, the ribbon aligner 514 is configured to center the ribbon 32b above the ribbon 32a in relation to the transverse direction, xxx

[0170] The ribbon 32a is directed to the glue applicator 516 after leaving the ribbon aligner 514. The glue applicator 516 is configured to apply a bonding element that bonds the attachment 32169405775Docket No. 194313.18502lips 60 to the wall 14, and forms the transverse seals 18 of the fully formed envelopes 10. The bonding element can be, for example, a pressure-sensitive cold adhesive 543. The glue applicator 516 includes a bottom gluing unit 544 and two side gluing units 546. Each side gluing unit 546 includes a single electronic glue applicator configured to apply the adhesive 543 to the respective outer edge portions of the ribbon 32a.

[0171] The bottom gluer 544 includes a plurality of electronic glue applicators configured to apply a transverse band of the adhesive 543 across the ribbon 32b, at locations on the ribbon 32a corresponding to the locations at which the transverse seals 18 of the envelopes 10 are to be formed. The glue applicator 516 includes a sensor configured to sense the registration marks printed on the ribbon 32a by the printing unit 504. The registration marks permit the glue applicator 516 to index the ribbon 32a to the bottom gluer 544 so that the bottom gluer 544 can apply the adhesive 543 at the proper locations on the ribbon 32a. The coater 538 can include an anilox roller and a doctor blade that meter the release coating 48 as it is applied to the ribbon 32a.

[0172] The ribbon 32b is directed to the glue applicator 518 after leaving the ribbon aligner 514. The glue applicator 518 is configured to apply the hot-melt adhesive 543 that forms the closure sealing element 24 of the fully formed envelopes 10. The glue applicator 518 includes extrusion dies that applies a transverse band of the hot-melt adhesive 543 across the layers of release coating 48 applied previously at the coating and curing station 512. The glue applicator 518 includes a sensor configured to sense the registration marks printed on the ribbon 32b by the printing unit 504. The registration marks permit the glue applicator 518 to index the ribbon 32a to the extrusion die so that the bottom gluer 544 can apply the adhesive 543 at the proper locations on the ribbon 32a.33169405775Docket No. 194313.18502

[0173] The ribbon 32a is drawn to the gusset and seam former 520 after leaving the glue applicator 516. The gusset and seam former 520 includes a first creasing station 600. The first creasing station 600 includes two rotary plows 601, a stationary mounting bracket 602, and a support frame 604. The mounting bracket 602 is fixed to and suspended from the support frame 604. Each plow 601 is mounted on the mounting bracket 602 so that the plow 601 can rotate in relation to the mounting bracket 602. The outer circumference of each plow 601, which acts as the contact surface between the plow and the ribbon 32b, is approximately V-shaped. The plows 601 are oriented so that the axis of rotation of each plow 601 is angled in relation to the horizontal direction, causing each plow 601 to be angled downward and outward (away from the centerline of the ribbon 32b), as shown in FIG. 11.

[0174] The first creasing station 600 also includes two stationary brushes 606, and two rollers 608. The rollers 608 are mounted for rotation on an axle 611 coupled to the support frame 604 via brackets 612. The brushes 606 are mounted on respective brackets 614 connected to the support frame 604. Each brush 606 is located adjacent to, and downstream of an associated plow 601. The rollers 608 are located downstream of the brushes 606.

[0175] The ribbon 32a leaves the glue applicator 516 in a substantially flat configuration. Each outer, or side-edge portion of the ribbon 32a passes between one of the plows 601 and its associated brush 606, with the plow 601 contacting the upward-facing surface of the ribbon 32a and the bristles of the brush 606 contacting downward-facing surface of the ribbon 32a. The interaction between the plows 601, the brushes 606, and the ribbon 32a causes the side-edge portions of the ribbon 32a to fold upward. In particular, the angled orientation of each plow 601 causes the plow 601 to urge the ribbon 32a downward and outward, while the brushes 606 urge the opposite surface of the ribbon 32a inward, causing the side edge portion of the ribbon 32a to 34169405775Docket No. 194313.18502fold into an approximately vertical orientation. This folding motion, in connection with the V-shaped outer circumference of the plow 601 acting against the ribbon 32a, imparts a first crease 610 to the ribbon 32a.[00176J Each plow 601 is positioned so that that the first crease 610 spaced from the adjacent side edge of the ribbon 32a by a distance about equal to the height, i.e., forward to rearward dimension, of the fully expanded gusset 33, plus about 0.25 inch to about 1.0 inch. In some embodiments, the first crease 610 can be spaced from the adjacent side edge of the ribbon 32a by a distance about equal to the height of the gusset 33 plus about 0.25 inch to about 0.75 inch. In some embodiments, the first crease 610 can be spaced from the adjacent side edge of the ribbon 32a by a distance about equal to the height of the gusset 33 plus about 0.5 inch.

[0177] Each roller 608 extends across the ribbon 32a to a point just short of the mid-point of the ribbon 32a, at a slight positive angle in relation to the ground. The rollers 608 engage the lower surface of the ribbon 32a, and support the ribbon 32a as the ribbon 32a passes through the first creasing station 600.

[0178] The gusset forming unit 510 also includes a second creasing station 620 located downstream of the first creasing station 600. The second creasing station 620 includes two creasers 622. Each creaser 622 is mounted in a respective housing 622, and each housing 622 is mounted on a respective bracket 626 connected to the support frame 604. The creasers 622 each have a leading surface 627 that is angled downward and inward, toward the centerline of the ribbon 32a, from the perspective of FIGS. 10 and 12. The bottom portion of the surface 627 and the adjoining portion of each creaser 622 define a sharp leading edge 628 of the creaser 622.35169405775Docket No. 194313.18502

[0179] The second creasing station 620 also includes two stationary brushes 629. Each brush 629 is mounted on a respective bracket 631 connected to the support frame 604 and is located below an associated creaser 622.[00180J Each creaser 622 is configured so that the leading edge 628 of the creaser 622 contacts the lower (now outside) surface of the ribbon 32a, on the side-edge portion of the ribbon 32a that was folded upward at the first creasing station 600. The leading edge 628 contacts the ribbon 32a between the first crease 610 and the side edge of the ribbon 32a. The corresponding brush 629 supports the lower surface of the ribbon 32a directly below the creaser 622. The interaction between the creaser 622, the brush 629, and the ribbon 32a imparts a second crease 630 in the ribbon 32a. In particular, the sharp leading edge 628 of the creaser 622 imparts the second crease 630 to the ribbon 32a (without cutting the ribbon 32a). The second crease 630 is spaced from the first crease 610 by a distance equal to about half the height of the fully expanded gusset 33.

[0181] At this point, the gussets 33 have been formed on both side of the ribbon 32a, and are in a folded state with the second panel 634 located above the first panel 632 from the perspective of FIG. 12-13. Each gusset 33 includes a first panel 632 defined between the first and second creases 610, 630, and a second panel 634 that adjoins the first panel 632 via the second crease 630. The panels 632, 634 each have a height, or front to rear dimension, about equal to half the height of the gusset 33. Also, as noted above, the first crease 610 was formed from the adjacent side edge of the ribbon 32a by a distance equal to the height of the gusset 33 plus about 0.25 inch to about 1.0 inch. Thus, a portion of the ribbon 32a between the second panel 630 and the adjacent side edge of the ribbon 32a extends outward, beyond the fold gusset 33, by about 0.25 inch to about 1.0 inch. These portions, or outer panels, of the ribbon 32a are denoted in FIG. 12- 36169405775Docket No. 194313.1850213 by the reference number 636. The outer panel portions 636 include the adhesive 543 that was applied to the surface of each outer panel portion 636 on ribbon 32a in the glue applicator 516.

[0182] The glue applicator 518 is located above the gusset and seam former 520. The ribbon 32b, upon leaving the glue applicator 518, travels along a downward-sloped path guided by a roller 539. The ribbon 32a, after having the gussets 33 formed thereon, travels along an upward-sloped path guided by another roller 539. The ribbons 32a, 32b previously were aligned ribbon aligner 514. The respective paths of the ribbons 32a, 32b eventually converge at the exit of the gusset and seam former 520, at which point the ribbon 32b becomes overlayed onto the ribbon 32a. The ribbons 32a, 32b then pass between rollers 639, which press the ribbons 32a, 32b together so that the adhesive 543 on the ribbon 32a forms a bond across between the ribbons 32a, 32b. As noted above, this bond forms the transverse seal 18 of the finished envelope 10. Also, the pressing of the ribbons 32a, 32b by the rollers 639 causes the adhesive of the closure sealing element 24 previously deposited on the release coating 48 on the ribbon 32b to bond to the ribbon 32a.

[0183] The width, or cross-direction dimension of the ribbon 32a is about equal to the width of the portion of the ribbon 32b located between the outer panel portions 636. Thus, the side-edge portions of the ribbon 32b each land on a respective panel 634 of the ribbon 32b when the aligned ribbons 32a, 32b converge, with the side edges of each ribbon 32a located directly over the boundary between the second panel 634 and its adjoining outer panel portion 636. Thus, the adhesive 543 previously deposited onto the upward-facing surface of each outer panel portion 636 remains exposed and not covered by the ribbon 32b.

[0184] The overlayed ribbons 32a, 32b enter the gusset and seam former 520 upon exiting the gusset forming unit 510. The gusset and seam former 520 folds the outer panel portions 636 of 37169405775Docket No. 194313.18502the ribbon 32b over and onto the upward facing surface of the ribbon 32b to form the attachment lips 60 of the envelope 10.

[0185] The gusset and seam former 520 includes a tray 650. The tray 650 has a substantially flat central portion 652, and two lips 654 that adjoin opposite sides of the central portion 652. Each lip 654 gradually rises from the central portion 652 in the machine direction and curls up and over the central portion 652 until the lip 654 is located over, and extends parallel to the central portion 652.

[0186] The tray 650 is configured so that the lips 654 fold the outer panel portions 636 of the ribbon 32a over and onto the upward facing surface of the ribbon 32b as the overlayed ribbons 32a, 32b travel through the gusset and seam former 520. In particular, the lips 654 are staggered so that the lip 654 on the right side of the tray 650 (from the perspective of FIG. 14) contacts the overlayed ribbons 32a, 32b before the lips 654 on the opposite side of the tray 650. The gusset and seam former 520 includes a roller 656 and a brush 658 configured to contact the upward facing surface of the upper ribbon 32b proximate the right lip 654 as the right lip 654 begins to lift and fold the outer panel portion 636 on the right side of the ribbon 32b. The roller 656 and the brush 658 exert a downward force on the ribbon 32b and the underlying ribbon 32a. As can be seen in FIG. 14, the shape of the lip 654, in combination with the downward restraining effect of the roller 656 and the brush 658, cause the outer panel portion 636 to fold progressively upward, and then over and onto the upward-facing surface of the ribbon 32b as the ribbons 32a, 32b are drawn through the lip 654. The folding of the outer panel portion 636 onto the ribbon 32b causes the adhesive 543 on the outer panel portion 636 to contact the upward-facing surface of the ribbon 32b. The pressure-sensitive adhesive 543 forms a bond between the outer panel portion 636 of attachment lip 60 and the ribbon 32b, thereby forming the side seam that connects 38169405775Docket No. 194313.18502the right gusset 33 and the adjoining ribbon 32a to the ribbon 32b. The gusset and seam former 520 includes another brush 658 located directly downstream of the right lip 654 to further smooth and press the outer panel portion 636 onto the upper ribbon 32b.[00187J The outer panel portion 636 on the left side of the ribbon 32a subsequently is folded up, and onto the upward facing surface of the ribbon 32b by the lip 654 located on the left side of the tray 650, in the same manner as described above in relation to the right outer panel portion 636. The gusset and seam former 520 includes an additional roller 656 and additional brushes 658 to restrain and smooth the ribbons 32a, 32b as, and after the outer panel portion 636 of attachment lip 60 is folded and adhered to the ribbon 32b to form the side seam that connects the left gusset 33 and the adjoining ribbon 32b to the ribbon 32a.

[0188] At this point, the ribbons 32a, 32b have been joined by the attachment lips 60 to form a web 78 of partially formed envelopes 10, and the gussets 33 are in a folded state. The web 78 next is directed to the die cutter 522, which forms the closure flap 42 and the cover 44 of each envelope 10 into their final respective shapes. In particular, the die cutter 522 is configured to make a generally triangular cut on each side of the respective upper (downstream) ends of each pre-formed envelope in the web 78. The die cutter 522 also makes semi-circular cuts 160 that define the stress-relief cutouts 162 on the pre-formed envelopes 10.

[0189] The die cutter 522 includes two dies 660. Each die 660 has a backing plate 661, and a blade 664 fixed to the backing plate 661. Each blade 664 has a straight portion and an adjoining curved portion that cause the blade 664 to make a cut that simultaneously defines the straight, angular outer edges of the closure flap 42 and the cover 44, and the stress-relief cutouts 162.

[0190] The die cutter 522 also includes a bottom support (not shown) and an actuator (also on shown). The dies 660 are mounted on an actuator (not shown). The web 78 is drawn through 39169405775Docket No. 194313.18502the die cutter 522 so that the web passes between the bottom support and the overlying dies 660 and actuator. The actuator is configured to move the dies 660 vertically, into and out of contact with the web 78, to make the cuts that define the edges of the outer edges of the closure flap 42, and the stress-relief cutouts 162. The bottom support acts as an anvil that supports the web 78 during the cutting process. The die cutter 522 can include a sensor (not shown) that senses the registration marks on the ribbon 38b so that the web 78 can be indexed to the actuator, allowing the cuts to be made at the proper locations along the web 78.

[0191] The web 78 is directed to the rotary cutter 524 after the above-noted cuts have been made in the closure flap 42 and the cover 44. The rotary cutter 524 is configured to cut the ribbon 32b to form the kiss cut 50 between the cover 44 and the wall 12 of the partially-formed envelope 10. The rotary cutter 524 also is configured to make the U-shaped cuts in the closure flap 42 and the cover 44, and to cut through the web 78 to sever the envelope 10 from the remainder of the web 78.

[0192] The rotary cutter 524 includes a drum 662, and actuator (not shown) configured to rotate the drum 662, and a bottom support (also not shown). The rotary cutter 524 also includes a first blade 664, a second blade 666, and a third blade (not shown) both mounted on the drum 662 so that the first blade 664, the second blade 666, and the third blade rotate with the drum 662.

[0193] The third blade is substantially straight, and is configured to form the kiss cut 50 in the partially-formed envelope 10. In particular, the third blade has a height that is selected so that the third blade cuts through the ribbon 32b as the web 78 passes between the third blade and the bottom support of the rotary cutter 524. The third blade also cuts through the underlying gussets40169405775Docket No. 194313.1850233, but does not cut through the remainder of the ribbon 32a. The third blade is configured so that the cut extends across the entire width of the web 78.

[0194] The rotary cutter 524 can include a sensor (not shown) that senses the registration marks on the ribbon 38b so that the web 78 can be indexed to the rotating drum 662, allowing the kiss cut 50 to be made at the proper location along the web 78, i .e., at the interface of the cover 44 and the wall 12 of the partially-formed envelope 10.

[0195] The second blade 666 is U-shaped, and forms the U-shaped cuts 119 in the closure flap 42a and the cover 44a. The second blade 666 has a height that is selected so that the second blade 666 cuts through both of the ribbons 32a, 32b as the web 78 passes between the second blade 666 and the bottom support of the rotary cutter 524. The second blade 666 is angularly spaced from the third blade on the drum 662 so that the proper spacing is maintained between the U-shaped cuts 119 and the kiss cut 50.

[0196] The first blade 664 is substantially straight and extends across the entire width of the web 78 . The first blade 664 severs the envelope 10 from the remainder of the web 78, and thus defines the upper edge of the severed envelope 10 and the bottom edge 22 of the adjacent envelope 10 on the web. The first blade 664 has a height that is selected so that the first blade 664 cuts through both of the ribbons 32a, 32b as the web 78 passes between the first blade 664 and the bottom support of the rotary cutter 524. The first blade 664 is angularly spaced from the second and third blades on the drum 662 so that the proper spacing is maintained between the upper edge of the envelope 10, and the U-shaped cuts 119 and the kiss cut 50.

[0197] Although the present solution has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In 41169405775Docket No. 194313.18502addition, while a particular feature of the present solution may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above-described embodiments. Rather, the scope of the present solution should be defined in accordance with the following claims and their equivalents.42169405775

Claims

Docket No. 194313.18502What is clamed is:

1. An envelope for holding an item, comprising:a first wall;a second wall overlying the first wall;a first gusset extending from the first wall;a first attachment lip extending from the first gusset, the first attachment lip overlaying and affixed to an exterior side of the envelope;wherein the first and second walls and the first gusset cooperatively define:a pocket located between the first and second walls, the pocket configured and dimensioned to contain the item, anda pocket opening allowing access to the pocket from an exterior of the envelope for loading the item into the pocket.

2. The envelope of claim 1, wherein the first attachment lip is configured to wrap around the second wall as the first attachment lip extends from the first gusset.

3. The envelope of claim 1, wherein the first attachment lip is affixed to an exterior surface of the second wall.

4. The envelope of claim 1, wherein the first gusset is unitary with the first wall and the first attachment lip.43169405775Docket No. 194313.185025. The envelope of claim 1, wherein the first attachment lip defines a seam between the first gusset and the second wall.

6. The envelope of claim 1, wherein the first seam is displaced from the first gusset.

7. The envelope of claim 1, further comprising a bonding element sealing the first attachment lip to the exterior side of the envelope.

8. The envelope of claim 7, wherein the bonding element is an adhesive.

9. The envelope of claim 1, wherein the first and second walls and the first gusset are made of paper.

10. The envelope of claim 1, wherein a side of the first gusset extends from the first wall and the first attachment lip extends from a second side of the gusset.

11. The envelope of claim 1, wherein:the first gusset includes a first panel extending from the first wall, and a second panel extending from the first panel; andthe first attachment lip extends from the second panel.

12. The envelope of claim 11, wherein:44169405775Docket No. 194313.18502the first panel is connected the first wall by a first living hinge between the first panel and the first wall; andthe second panel is connected the first panel by a second living hinge between the first panel and the second panel.

13. The envelope of claim 12, wherein the first living hinge is configured the move into and out of the envelope pocket as the first wall and the second wall move toward and away from each other.

14. The envelope of claim 11, wherein the first panel and the second panel define a convex bend as the first wall and the second wall move toward each other.

15. The envelope of claim 1, wherein a bottom side of the first wall is affixed to a bottom side of the second wall.

16. The envelope of claim 1, further comprising a flap hingedly connected to the first flexible wall to rotate between:an open position, allowing access to the pocket through the pocket opening, and a closed position in which the flap extends from the first flexible wall, across the pocket opening and onto the second flexible wall to attach thereto, thereby closing the pocket opening.45169405775Docket No. 194313.1850217. The envelope of claim 1, further comprising a bonding element positioned on the first wall and / or second wall and configured to seal first wall to the second flexible wall to close the pocket opening.

18. The envelope of claim 17, wherein the bonding element is positioned on an interior surface of first wall and / or the second wall.

19. The envelope of claim 1, wherein the first wall and / or the second wall comprises at least two overlying layers affixed to each other about an interlayer border that encloses a plurality of sides of an interlayer region defined by the at least two overlying layers.

20. The envelope of claim 1, wherein the first and second walls are flexible.

21. The envelope of claim 1, further comprising:a second gusset extending from the first wall;a second attachment lip extending from the second gusset, the second attachment lip overlaying and affixed to the exterior side of the envelope.

22. The envelope of claim 21, wherein the first and second gussets cooperate to permit the first and second walls to move in relation to each other.

23. The envelope of claim 1, wherein:46169405775Docket No. 194313.18502the first gusset is configured to contract and expand as the first and second walls move toward and away from each other in a first and second direction; andthe first attachment lip as a transverse dimension in a third direction substantially perpendicular to the first and second directions.

24. An envelope for holding an item, comprising:a first wall;a second wall overlying the first wall; anda first gusset having a first end extending from the first wall, and a second end attached to the second wall by a first seam displaced from the first gusset and located on an exterior side of the envelope;wherein the first and second walls and the gusset cooperatively define:a pocket located between the first and second walls, the pocket configured and dimensioned to contain the item, anda pocket opening allowing access to the pocket from an exterior of the envelope for loading the item into the pocket.

25. The envelope of claim 24, wherein the first seam is defined by a first attachment lip extending from the second end of the first gusset.

26. The envelope of claim 24, wherein the first end of the first gusset is unitary with the first wall.47169405775Docket No. 194313.1850227. The envelope of claim 25, wherein the first seam is further defined by a bonding element affixing the first attachment lip to the second wall.

28. The envelope of claim 24, wherein the first gusset is devoid of any seams.

29. The envelope of claim 24, wherein:the first gusset is configured to contract and expand as the first and second walls move toward and away from each other in a first and second direction; andthe seam is displaced from the first gusset in a third direction substantially perpendicular to the first and second directions.

30. The envelope of claim 24, further comprising a second gusset having a first end extending from the first wall, and a second end attached to the second wall by a second seam displaced from the second gusset and located on an exterior side of the envelope.

31. A web of pre-formed envelopes, comprising:a first ribbon of material having a first fold, and a second fold located between the first fold and a first longitudinal edge of the first ribbon, the first and second folds defining a first gusset, the first ribbon having a first attachment lip defined between the first gusset and a first longitudinal edge of the first ribbon; anda second ribbon of material overlayed on the first ribbon so that a portion of the second ribbon adjacent a first longitudinal edge of the second ribbon is positioned on the first gusset,48169405775Docket No. 194313.18502and the first attachment lip extends transversely beyond the first longitudinal edge of the second ribbon.

32. The web of claim 31, further comprising a bonding element located on the first attachment lip.

33. The web of claim 31, further comprising a bonding element extending transversely across a substantial entirely of a width of the first ribbon.

34. The web of claim 31, wherein the first and second folds extend in a longitudinal direction of the first ribbon.

35. The web of claim 31, wherein:the first ribbon has a third fold, and a fourth fold located between the third fold and a second longitudinal edge of the first ribbon, the third and fourth folds defining a second gusset, the first ribbon having a second attachment lip defined between the second gusset and a second longitudinal edge of the first ribbon; anda portion of the second ribbon adjacent a second longitudinal edge of the second ribbon is positioned on the second gusset, and the second attachment lip extends transversely beyond the second longitudinal edge of the second ribbon.

36. A method of forming an envelope, comprising:folding a first ribbon of material about a first fold line;49169405775Docket No. 194313.18502folding the first ribbon about a second fold line located between the first fold line and a longitudinal edge of the first ribbon, the first and second fold lines defining a first gusset;overlaying a second ribbon of material on the first ribbon so that a portion of the second ribbon adjacent a first longitudinal edge of the second ribbon is positioned on the first gusset, and an attachment lip defined on the first ribbon between the first gusset and a first longitudinal edge of the first ribbon extends transversely beyond the first longitudinal edge of the second ribbon;folding the first attachment lip so that the first attachment lip overlaps the second ribbon; andaffixing the first attachment lip to the second ribbon.

37. The method of claim 36, further comprising folding the first attachment lip over the second ribbon.

38. The method of claim 37, further comprising folding the first attachment lip by about 180 degrees.

39. The method of claim 37, further comprising folding the first attachment lip onto the second ribbon.

40. The method of claim 39, further comprising pressing the first attachment lip into the second ribbon after folding the first attachment lip onto the second ribbon.50169405775Docket No. 194313.1850241. The method of claim 36, further comprising affixing the first attachment lip to the second ribbon using a bonding element.

42. The method of claim 41, further comprising:applying the bonding element to the first attachment lip; andfolding the first attachment lip onto the second ribbon so that the bonding element contacts the second ribbon.

43. The method of claim 36, further comprising forming the first and second fold lines along a longitudinal direction of the first ribbon.

44. The method of claim 36, wherein the first fold line is located at a distance from the first longitudinal edge of the first ribbon equal to a combined width of the first gusset and the first attachment lip.

45. The method of claim 36, further comprising:providing a web of the material; andslitting the web of material to form the first and second ribbons of the material.

46. The method of claim 45, further comprising slitting the web of material so that a width of the first web is greater than a width of the second web.51169405775Docket No. 194313.1850247. The method of claim 36, further comprising aligning the second ribbon with the first ribbon in a transverse direction of the first and second ribbons.

48. The method of claim 36, wherein folding the first ribbon of material about the first fold line comprises creasing the first ribbon along the first fold line using a rotary plow.

49. The method of claim 36, wherein folding the first ribbon of material about the second fold line comprises creasing the first ribbon along the second fold line using a stationary creaser.

50. The method of claim 36, further comprising:applying a bonding element transversely across at least one of the first and second ribbons; andpressing the first ribbon into the second ribbon to form a transverse seal between the first and second ribbons.

51. The method of claim 36, further comprising:applying a release coating to one of the first and second ribbons; andapplying a bonding element to the release coating, the first ribbon, and / or the second ribbon so that the release coating and the bonding element face each other when the second ribbon is overlayed onto the first ribbon.

52. The method of claim 36, further comprising forming a separation region in one of the first and second ribbons proximate the release coating.52169405775Docket No. 194313.1850253. The method of claim 52, wherein forming a separation region in one of the first and second ribbons proximate the release coating comprises cutting the first or the second ribbon, or forming a line of weakness in the first or the second ribbon.

54. The method of claim 36, further comprising:folding the first ribbon about a third fold line;folding the first ribbon about a fourth fold line located between the third fold line and a second longitudinal edge of the first ribbon, the third and fourth fold lines defining a second gusset;overlaying the second ribbon of material on the first ribbon so that a portion of the second ribbon adjacent a second longitudinal edge of the second ribbon is positioned on the second gusset, and a second attachment lip defined on the first ribbon between the second gusset and a second longitudinal edge of the first ribbon extends transversely beyond the second longitudinal edge of the second ribbon;folding the second attachment lip so that the second attachment lip overlaps the second ribbon; andaffixing the second attachment lip to the second ribbon.

55. A system for forming an envelope, comprising:a forming device configured to form a first and a second fold line in a first and a second ribbon, the first and second fold lines defining a first gusset in the first ribbon; and53169405775Docket No. 194313.18502a folding device configured to fold a first attachment lip defined on the first ribbon between the first gusset and a longitudinal edge of the first ribbon over a second web, the second web overlay ed on the first web so that a first portion of the second web adjacent a longitudinal edge of the second web is positioned on the first gusset.

56. The system of claim 55, wherein the forming device comprises a rotary plow configured to form the first fold line.

57. The system of claim 56, wherein the forming device further comprises a first brush configured to cooperate with the rotary plow to form the first fold line.

58. The system of claim 56, wherein the forming device further comprises a stationary creaser configured to form the second fold line.

59. The system of claim 56, wherein the forming device further comprises a second brush configured to cooperate with the stationary creaser to form the second fold line.

60. The system of claim 55, wherein the folding device is configured to rotate the first attachment lip over the second ribbon.

61. The system of claim 60, wherein the folding device is configured to rotate the first attachment lip onto the second ribbon.54169405775Docket No. 194313.1850262. The system of claim 59, wherein the folding device is configured to rotate the first attachment lip by about 180 degrees.

63. The system of claim 55, further comprising a slitter configured to slit a web of material to form the first and second ribbons.

64. The system of claim 55, further comprising an aligner configured to align the second ribbon with the first ribbon in a transverse direction of the first and second ribbons.

65. The system of claim 55, further comprising a first glue applicator configured to apply a bonding element to the first attachment lip of the first ribbon.

66. The system of claim 65, wherein the first glue applicator is further configured to apply the bonding element in a band extending transversely across the first ribbon.

67. The system of claim 55, further comprising a release-coating applicator configured to apply a release coating to the first ribbon or the second ribbon.

68. The system of claim 67, further comprising an ultraviolet light configured to cure the release coating after application of the release coating to the first ribbon or the second ribbon.5169405775Docket No. 194313.1850269. The system of claim 67, further comprising a second glue applicator configured to apply a bonding element to the release coating, the first ribbon, or the second ribbon so that the boding element face the release coating.

70. The system of claim 69, further comprising a first cutting device configured to separate or partially separate a portion of the first web or the second web containing the release coating from an adjacent portion of the first web or the second web.56169405775

Images